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Improved Combustion Efficiencies - Control Systems for Process Heaters and Boilers
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This paper presents the results of a study of the importance and applications of modern combustion control systems for retrofitting existing boilers and heaters to increase combustion efficiency. Conventional heater control and its deficiencies are discussed and the need for modern control is stressed. Modern control systems offered by leading manufacturers are discussed in detail. Modern combustion control systems are designed to provide safe and proper combustion, desired air/fuel ratio, reduced excess air to an optimum minimum (in the range of 3-5%); also to provide the required plant energy demand with varying factors such as BTU input of the fuel, feed flow rate, etc., and for dual fuel firing. Cost estimates for various control system configurations are included and discussed. Conclusions from the study of control systems provided by various manufacturers are: 1) It is possible to design a control system to reduce excess air to 3-5%. 2) The cost of these control systems will be approximately $50-60,000. 3) Resulting fuel savings from retrofitting will be 5-15%, and will payout in less than a year.
Varma, A. C.; Prengle, H. W. (1979). Improved Combustion Efficiencies - Control Systems for Process Heaters and Boilers. Energy Systems Laboratory (http://esl.tamu.edu). Available electronically from