Unlock energy savings you thought were already optimised
Every plant manager is aware of material and labour costs, but how many truly understand the impact of energy expenses on production? In industries relying on process heating, energy costs are substantial yet often viewed as a fixed overhead. While negotiating better fuel and electricity rates is standard practice, are other cost-saving opportunities being overlooked by using an industrial burner controls?
Car engines and industrial burners: A parallel
Car engines and industrial burners share similarities: both convert fuel to energy, utilise combustion, and produce emissions. However, car engines have evolved into high-performance, efficient machines. Advancements like fuel injection, engine management systems, lambda control, and exhaust gas recirculation have optimised performance and reduced emissions.
Industrial Burners are undergoing a similar transformation. Mechanical cam fuel-to-air ratio controls, akin to carburetors, are being replaced by electronic burner controls (sometimes referred to as burner management systems or combustion control systems). Oxygen trim, the equivalent of lambda control, and flue gas recirculation are reducing emissions. Other enhancements, like increased turn-down ratios, fan speed control, and advanced control strategies, have improved efficiency and performance. Software features like boiler lead/lag control and enhanced communication systems further optimise burner operation and data flow.
Most of these innovations have evolved over the last 25 years and can be retrofitted to existing linkage-based systems, providing significant benefits in energy savings, emissions reduction, and operational flexibility by freeing up personnel for other critical tasks.
Mechanical cams and linkages: A limiting legacy
Consider a typical industrial boiler with mechanical cam control. At high fire, the oxygen level is set slightly above optimal to ensure safety despite varying conditions. Changes in ambient temperature, air density, fuel viscosity, gas supply pressure, and other factors cause fluctuations in combustion.
Mechanical cams force burner designers and operators to make compromises between safety and performance, often leading to inefficiencies. For example, a gas burner may have a turn-down ratio of 7:1, while dual-fuel burners may only achieve 4:1, resulting in frequent on-off cycles. A boiler without a burner management system that cycles frequently can waste both energy and time.
Electronic controls: The key to optimised efficiency
Upgrading to electronic fuel-air ratio controls eliminates many of the inefficiencies of mechanical systems. These systems allow different fuel and air settings for each fuel by using servo-motors to program the valve positioning. Benefits include:
- Increased Efficiency:
Linkage-less burners can reduce energy consumption by up to 1%, eliminating mechanical backlash. - Improved Turn-Down Ratio:
Accurate valve positioning reduces on-off cycles, minimising purge requirements and saving up to 5% in operating costs. - Fan Speed Control:
Lower fan speeds improve low-fire efficiency, potentially saving up to 80% in electrical energy. - Oxygen Trim:
Real-time adjustments optimise combustion, reducing excess air and achieving 2-3% energy savings. - Boiler Sequencing & Communication Software:
Integrated software provides real-time data and trend analysis, leading to operational savings.
Upgrade your burner controls and save
Switching to electronic burner controls offers more than energy savings—it enhances performance and safety. ETC’s 6000 series provides advanced combustion control, with air-fuel ratio controllers and connectivity options like RS-485, ModBus, and ProfiBus, making it easier than ever to optimise boiler performance and make informed decisions.