28 | Plant & Works Engineering www.pwemag.co.uk February/March 2025 Energy & Environmental Management Focus on: Boilers, Burners & Controls Industrial burner technology plays a crucial role in the UK’s manufacturing and processing sectors, where energy consumption remains a significant concern. The push for efficiency has never been greater, driven by rising fuel costs, stringent environmental regulations, and the broader imperative to reduce carbon emissions. Achieving optimal energy performance in industrial burners is not simply a matter of installing new equipment; it requires a holistic approach that integrates fuel efficiency, advanced control systems, and waste heat recovery. The efficiency of an industrial burner is determined by its ability to convert fuel into useful heat while minimising losses. One of the primary challenges in achieving this is excess air. While some level of excess air is necessary to ensure complete combustion and prevent the formation of carbon monoxide, too much dilutes the combustion gases, increasing heat loss and reducing overall efficiency. Proper burner tuning, combined with oxygen trim controls, can dynamically adjust air-fuel ratios to maintain the optimal balance. These systems use real-time data from oxygen sensors to make continuous fine-tuned adjustments, significantly improving fuel utilisation. Modern burner technology increasingly incorporates flue gas recirculation (FGR), a technique that redirects a portion of exhaust gases back into the combustion chamber. This not only reduces nitrogen oxide (NOx) emissions but also enhances thermal efficiency by recovering heat that would otherwise be lost. When paired with condensing economisers, which capture latent heat from exhaust gases, overall efficiency can be raised significantly, making it possible to achieve fuel savings of 10% or more depending on the application. Better burner modulation Another avenue for improving efficiency is through better burner modulation. Traditional on/off or high/low burners operate with inherent inefficiencies, frequently cycling and causing thermal fluctuations that waste energy. Fully modulating burners, by contrast, adjust their firing rate in response to process demand, maintaining a steady and efficient combustion process. These systems, particularly when integrated with advanced combustion control software, offer precise regulation of flame characteristics, ensuring that energy is used as effectively as possible. Beyond direct combustion efficiency, effective insulation and heat containment within industrial processes further enhance performance. Refractory materials and hightemperature insulation around burners and combustion chambers reduce radiative heat losses. Similarly, optimising air preheating can significantly enhance thermal efficiency. Preheated combustion air reduces the amount of fuel needed to achieve the required process temperatures. Regenerative and recuperative burners, which use heat exchangers to capture and recycle waste heat, can offer significant efficiency gains, often exceeding 80% thermal efficiency in well-designed systems. While hardware improvements contribute substantially to efficiency, digitalisation is becoming an increasingly powerful tool. Smart monitoring systems with real-time data analytics allow for predictive maintenance, identifying potential efficiency losses before they escalate into costly problems. Energy management software can track burner performance, emissions levels, and fuel usage, offering actionable insights for ongoing optimisation. In large industrial settings, the integration of machine learning algorithms can help detect patterns and make automated efficiency adjustments, reducing human error and ensuring peak performance at all times. Practical implementation Despite these technological advances, practical implementation remains a challenge for many businesses. Retrofitting existing burner systems to improve efficiency is often more economically viable than full replacement, particularly in industries where capital expenditure is tightly controlled. Simple upgrades such as variable speed drives on fan motors, improved burner controls, and better insulation can yield significant energy savings Optimising industrial burner technology enhances efficiency, reduces emissions, and cuts costs. Through advanced modulation, fuel flexibility, and digital monitoring, businesses can achieve significant energy savings while meeting sustainability and regulatory goals. PWE reports. Enhancing efficiency in burner technology without the need for extensive overhauls. One of the emerging considerations in burner efficiency is fuel flexibility. As the UK transitions towards lower-carbon energy sources, many industrial processes are exploring hydrogen and biofuels as alternatives to natural gas. The combustion characteristics of these fuels differ, requiring adaptable burner designs that can handle multiple fuel types without sacrificing efficiency. Some manufacturers are now developing hybrid burners capable of seamlessly switching between conventional and alternative fuels, providing resilience against future energy market fluctuations. The financial case for improved burner efficiency is compelling. Reduced fuel consumption translates directly into lower operating costs, while regulatory compliance minimises the risk of financial penalties. Additionally, many efficiency measures qualify for government incentives and funding schemes aimed at reducing industrial carbon emissions. With energy prices remaining volatile, even modest efficiency gains can offer substantial long-term savings. Ultimately, improving burner efficiency requires a strategic approach. Rather than viewing efficiency upgrades as isolated technical adjustments, businesses should consider them as part of a broader energy management strategy. Combining advanced combustion technologies, waste heat recovery, digital monitoring, and alternative fuels will ensure that industrial processes remain competitive in an increasingly sustainabilityfocused economy. As energy efficiency continues to shape the future of industrial heating, those who prioritise optimisation today will be best positioned for long-term success.
RkJQdWJsaXNoZXIy MjQ0NzM=