How to Enhance Combustion Efficiency through Flue Gas

Analysis and Air/Fuel Flow

By: Mehul Patel Hi-Tech CAE

This article is a study about flue gas oxygen and combustibles, and variable air fuel pre-combustion
flows to enhance combustion efficacy of industrial boilers, steam generators, furnaces, ovens, smelters,
and process heaters using flue gas analysis. It also depicts that mass flow measurement of natural gas
and combustion air flow delivers indispensable evidence for a facility to function at optimal efficacy and
negligible emissions using combustion air flow analysis.

By comprehending the subtle balance of additional air-and-fuel usage, we can measure both the
concentrations of oxygen and combustibles in the exhaust gas to produce air-to-fuel control strategy.
The measurement of O2 and CO in unison is critical here. To preserve the optimal combustion efficacy
incessantly, measurements of both flue gas oxygen and combustibles are essential using combustion air
flow analysis and flue gas analysis.
When defining the carbon monoxide content from the flue gas, we are able to make alterations to the
operation because the CO content characterizes the unburnt fuel which is squandered due to
inadequate air. On the other hand, by calculating the O2 in the stack gas we are able to see the loss of
energy from too much surplus air.
Oxygen and combustion analyzers can deliver unceasing sampling and flue gas analysis making
scrutinizing oxygen and combustibles in the stack gases a way to capitalize on combustion efficiency.
Ideal combustion can be obtained at varied air-to-fuel ratios to resemble with different operating loads.
This makes it stimulating to utilize oxygen analyzers unaided to regulate excess air. In addition to this, a
patchy supply of oxygen in the flue gas could affect oxygen level disparities.
Furthermore, we scrutinize variable air and fuel pre-combustion flow using combustion air flow analysis
to improve efficacy. Burner management systems augment the air-to-fuel ratio for maximum efficacy
and negligible unburnt combustibles. A ratio flow approach is critical in safe and cost-effective operation
of fired heaters, furnaces, boilers and similar combustion processes. The number one condition for that
is to define process variable signals by gauging the mass flow of the gas flow and combustion air flow
rate using combustion air flow analysis. Since combustion is dictated by mass, it is ideal to evaluate mass
flow rather than volumetric flow.
Mass flow measurement of natural gas and combustion air flow using combustion air flow analysis
offers critical evidence for a facility to function at optimal efficacy and negligible emissions.
Furthermore, calculating combustion air flow can be tough as it is expected to have high flow rates at
low pressures through asymmetrical and outsized ducts. Whirls and turbulence in permutation with
inadequate conventional runs makes it intricate to attain the anticipated flow profiles which can show a
discrepancy with different operating loads.
Calibration precision needs to be good and repeatability is important. Fine-tuning the boiler enhances
the combustion efficiency. During combustion fine-tuning the air-to-gas fuel rates are enhanced at
different boiler loads. This fine-tuning encompasses gauging air and gas mass flow rates along with O2
and CO concentration, NOX concentration (if appropriate), outlet temperature, and flue gas
recirculation flow settings (if appropriate). In air flow monitoring, when setting the fuel flow the
combustion air flow is adjusted to match the gas flow to accomplish the anticipated air-to-gas ratio. The
meter must provide repeatable flow measurement when functioning at the same parameters on a
different day. Computing natural gas flow to the combustion source using combustion air flow analysis
can be useful to enhance overall combustion efficiency.
If you are looking to enhance combustion efficiency, you need help of Hi-Tech CAE a professional
engineering company offering combustion analysis services, & many more. They provide comprehensive
engineering CAD services utilizing state-of-the-art infrastructure. Some of the CFD services they offer
their global clientele includes: aerodynamic analysis services, hydrodynamic analysis services,
combustion analysis services, custom UDF development, Turbomachinery analysis services, laminar and
turbulent flows, fluid flow structure interaction, thermal analysis, conjugate/radiation heat transfer,
multiphase flow, steady state and transient flow, incompressible & compressible fluid flows, rotating
machinery, moving mesh, and CFD consulting services.
Main Source: http://www.hitechcae.com/blog/enhance-combustion-efficiency-through-flue-
gas-analysis/
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