Recently, considerable attention has been directed to the furnace combustion area, for furnace optimization and emissions limitations. New technologies are being explored to enhance optimization in all types of processing facilities.
As outlined in this article, not many changes are being done in this area in today’s operations:
“Furnace or boiler operations are supported by standardized procedures and operator experience, rather than by effective online information and optimized flame control. It is surprising that a chemical process such as combustion, with an impressive economic and environmental impact worldwide, still relies on nearly archaic controls.”
There are many economic and business related reasons for monitoring and controlling the furnace, to optimize it for best results. Economic reasons include environmental regulation of reducing NOx emissions, and environmental safety issues and personnel safety are always at the top of the priority list. In addition, there are business-related issues which motivate organizations to monitor and control the combustion area: increase fuel efficiency, reduce unnecessary shut downs because of tube or furnace damage, safety of personnel and equipment, and increased capacity.
“Combustion improvement offers the greatest potential for economic savings regarding the operation of industry boilers and furnaces. Nevertheless, the combustion process is difficult from the operator’s point of view because of limited information and feedback. For this operating unit, fuel costs are the greatest operating expense, and inappropriate fuel monitoring and oxygen monitoring make furnace optimization very unclear.”
The article outlines current operating conditions throughout the industries that utilize furnaces and boilers, and why furnace optimization is important in these economic and business related issues. The case history of measuring of the combustion area, and making the improvements are necessary, but reliable and immediate feedback of information to the operators is very important to make this happen. The example illustrated is a point in time, of a very small sample in the combustion area. As stated,
“Efficiency and emissions in industrial furnaces depend on the correct distribution of fuel and air supplies to the combustion process.”
We believe the article is correct in its analysis of current conditions, and that if correct adjustments are made, will improve these economic and business issues. The savings from optimizing the furnace will justify the technology and modified enhancements to the furnace and boilers.
One of the new technologies addressing this problem is actually the solution. The FurnaceMANAGER system, from Increase Performance, which monitors the furnace (combustion area) 24/7/365, monitoring all tubes and burners, relays feedback through analytical software back to the control room, giving operators the necessary information to adjust the furnace conditions for best furnace optimization.
