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Boiler Combustion Tuning and Analysis (Part 1) - Boiling Point

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00:00:00.060
well traditional burners have been fired
00:00:02.060 00:00:02.070 in boilers like these for many years
00:00:04.100 00:00:04.110 there's a lot more going on than just a
00:00:06.289 00:00:06.299 bunch of heat we're gonna talk
00:00:07.430 00:00:07.440 combustion today on the boiling point
00:00:17.680 00:00:17.690 well welcome to the boiling point always
00:00:20.330 00:00:20.340 good to see you glad that you spent some
00:00:21.950 00:00:21.960 time with us
00:00:22.670 00:00:22.680 we've got drilled blame appreciate you
00:00:24.500 00:00:24.510 stopping by again he's always really
00:00:27.500 00:00:27.510 anxious to get in front of the camera um
00:00:29.419 00:00:29.429 so I always like going out with Gerald
00:00:32.330 00:00:32.340 when we talk about this particular
00:00:34.100 00:00:34.110 subject he's able to explain this in a
00:00:37.220 00:00:37.230 very elementary way and I thought we'd
00:00:40.400 00:00:40.410 share a little bit about combustion
00:00:42.260 00:00:42.270 today so drill one should just talk a
00:00:43.670 00:00:43.680 little bit about some of the things that
00:00:44.930 00:00:44.940 we do here where and how we actually
00:00:47.840 00:00:47.850 explain combustion well what I kind of
00:00:51.049 00:00:51.059 wanted to talk about was our customers
00:00:53.840 00:00:53.850 in general they you know they want their
00:00:56.510 00:00:56.520 boiler to run they look in they see a
00:00:58.729 00:00:58.739 flame everything's good
00:01:00.709 00:01:00.719 steam is being made and they don't work
00:01:03.470 00:01:03.480 with it all day every day but they just
00:01:05.539 00:01:05.549 want it to run so they don't necessarily
00:01:06.980 00:01:06.990 know if there's a difference between one
00:01:08.510 00:01:08.520 flame or the next so that's one of the
00:01:10.789 00:01:10.799 things I wanted to talk about as well
00:01:12.230 00:01:12.240 we'll get into some technology
00:01:14.179 00:01:14.189 differences and how things have advanced
00:01:15.920 00:01:15.930 over the years but one of the things I
00:01:18.440 00:01:18.450 wanted to get into and I had some people
00:01:19.940 00:01:19.950 a lot smarter than me put this together
00:01:21.890 00:01:21.900 and this is a a typical situation it
00:01:25.999 00:01:26.009 would change furnace size might change
00:01:29.149 00:01:29.159 this a little bit the type of burner
00:01:30.649 00:01:30.659 might change this a little bit for but
00:01:32.600 00:01:32.610 for conversation purposes this
00:01:34.190 00:01:34.200 illustrates a lot of good fundamentals
00:01:35.960 00:01:35.970 regarding that all flames are not equal
00:01:38.649 00:01:38.659 because a lot of the things that are
00:01:40.670 00:01:40.680 going on today we talked about fgr that
00:01:44.780 00:01:44.790 means flue gas recirculating and that's
00:01:46.730 00:01:46.740 utilized a lot of times in order to
00:01:49.039 00:01:49.049 lower NOx everyone's got a lot of green
00:01:52.190 00:01:52.200 initiatives out there to keep emissions
00:01:53.990 00:01:54.000 down and but by and large that has a
00:01:58.270 00:01:58.280 negative effect in an efficiency effect
00:02:01.219 00:02:01.229 on on your system so I wanted to kind of
00:02:04.520 00:02:04.530 talk about that and illustrate how that
00:02:07.190 00:02:07.200 can impact what we do
00:02:09.570 00:02:09.580 today a guy will typically look at at
00:02:13.020 00:02:13.030 his flame and say oh you know it's nice
00:02:14.550 00:02:14.560 and blue it looks good but that isn't
00:02:16.740 00:02:16.750 how you define flame quality it might be
00:02:19.770 00:02:19.780 a clean flame and that's great but it
00:02:21.900 00:02:21.910 might be highly inefficient and what
00:02:24.120 00:02:24.130 I've got here is some curves regarding
00:02:26.850 00:02:26.860 flame temperature and I didn't do this
00:02:28.950 00:02:28.960 math I had someone do some thermal
00:02:30.630 00:02:30.640 calculations for me that's much smarter
00:02:32.340 00:02:32.350 than I but this kind of goes over the
00:02:34.560 00:02:34.570 fundamentals of what's actually going on
00:02:36.360 00:02:36.370 in your boiler what we want to look for
00:02:38.760 00:02:38.770 what we want to avoid this first curve
00:02:42.180 00:02:42.190 that we're looking at here is is with
00:02:43.950 00:02:43.960 zero fgr and that's kind of where I'm
00:02:45.930 00:02:45.940 going to base the conversation so as you
00:02:48.060 00:02:48.070 can see here as you add fgr your
00:02:50.880 00:02:50.890 decrease in flame temperature so let's
00:02:53.370 00:02:53.380 talk about we don't have any fgr from
00:02:55.830 00:02:55.840 the beginning a lot of people don't have
00:02:57.630 00:02:57.640 new low NOx burners at this point and
00:03:00.420 00:03:00.430 what what what they're often going to
00:03:02.880 00:03:02.890 see is we talk about excess there oh
00:03:06.540 00:03:06.550 twos as an example fifteen percent
00:03:09.140 00:03:09.150 excess air is almost three percent o2
00:03:13.320 00:03:13.330 and that's typical and the engineering
00:03:15.990 00:03:16.000 that usually happens with traditional
00:03:17.400 00:03:17.410 equipment is that they're hitting three
00:03:19.080 00:03:19.090 percent at high fire the problem is as
00:03:22.470 00:03:22.480 you come down
00:03:23.670 00:03:23.680 a typical firing range you're going to
00:03:26.220 00:03:26.230 see excess airs go up excess air and the
00:03:29.070 00:03:29.080 o2 level so as an example if we had 30
00:03:31.590 00:03:31.600 percent excess air and we're in a lower
00:03:33.090 00:03:33.100 firing range we're going to see a lower
00:03:35.370 00:03:35.380 flame temperature higher Oh twos and you
00:03:38.070 00:03:38.080 see us coming down the curve just going
00:03:40.620 00:03:40.630 from fifteen to thirty percent we could
00:03:43.110 00:03:43.120 see a drop close to three hundred
00:03:44.699 00:03:44.709 degrees in flame temperature so I'm
00:03:47.610 00:03:47.620 trying to illustrate here that all
00:03:49.050 00:03:49.060 flames are not equal and you can see as
00:03:51.420 00:03:51.430 we add flue gas recirculation we lower
00:03:54.270 00:03:54.280 those temperatures further often I'll
00:03:56.490 00:03:56.500 see systems that might be 40 or 50
00:03:58.530 00:03:58.540 percent excess air getting up here into
00:04:00.270 00:04:00.280 the six and seven percent o2 ranges and
00:04:02.910 00:04:02.920 you can see where that can bring it down
00:04:05.040 00:04:05.050 you know four or five six hundred
00:04:06.780 00:04:06.790 degrees in flame temperature so all
00:04:09.900 00:04:09.910 flames are not created equal and the
00:04:11.850 00:04:11.860 things we're wanting to avoid by
00:04:13.380 00:04:13.390 understanding this is avoid flame
00:04:15.900 00:04:15.910 quenching which is what's occurring here
00:04:17.610 00:04:17.620 with the lowering of the temperature
00:04:18.890 00:04:18.900 which is necessary to some degree when
00:04:21.630 00:04:21.640 we get into
00:04:22.300 00:04:22.310 knocks but how much flue gas we have to
00:04:25.900 00:04:25.910 add is going to impact how efficient
00:04:28.450 00:04:28.460 that particular system is and not all
00:04:30.640 00:04:30.650 low NOx are the same in doing this too
00:04:34.570 00:04:34.580 we want to avoid furnace cooling so if
00:04:36.760 00:04:36.770 we lower our temperatures we're
00:04:37.960 00:04:37.970 increasing the air now we've got our
00:04:39.550 00:04:39.560 heat exchanger battling against us and
00:04:42.580 00:04:42.590 we want to avoid high velocities a lot
00:04:44.830 00:04:44.840 of systems traditional systems in
00:04:47.379 00:04:47.389 particular they can use lower horsepower
00:04:50.800 00:04:50.810 fans because the velocities are running
00:04:53.379 00:04:53.389 through there quickly and the heat
00:04:54.520 00:04:54.530 exchanger can't perform exactly like
00:04:56.230 00:04:56.240 we'd like it
00:04:56.950 00:04:56.960 so by avoiding some of these things
00:04:58.900 00:04:58.910 we're looking for better heat transfer
00:05:00.420 00:05:00.430 we also want to look for less
00:05:02.440 00:05:02.450 maintenance so there's a lot of
00:05:03.670 00:05:03.680 equipment out there that has fewer
00:05:04.990 00:05:05.000 moving parts and those are the kinds of
00:05:07.540 00:05:07.550 things we're wanting to implement into
00:05:09.190 00:05:09.200 our combustion system but these are just
00:05:11.650 00:05:11.660 some of the fundamentals that the
00:05:13.090 00:05:13.100 average person who's not dealing with
00:05:15.490 00:05:15.500 this kind of thing every day simply
00:05:17.170 00:05:17.180 looks in the peephole and goes I got a
00:05:18.820 00:05:18.830 flame and why is your flame any
00:05:21.550 00:05:21.560 different and these are some of the
00:05:22.810 00:05:22.820 characteristics that really cause that
00:05:24.730 00:05:24.740 to be different well don't worry
00:05:27.400 00:05:27.410 there's a lot more of that video if
00:05:29.409 00:05:29.419 you'd like to see more you can click
00:05:31.150 00:05:31.160 right here and see more of that
00:05:33.130 00:05:33.140 discussion between Gerald and myself
00:05:35.440 00:05:35.450 don't forget to Like us on Facebook
00:05:37.080 00:05:37.090 maybe follow us on Twitter on the social
00:05:39.730 00:05:39.740 media and maybe send us a tweet don't
00:05:42.070 00:05:42.080 forget that boiler warehouse.com always
00:05:44.350 00:05:44.360 love to see you hope you have a great
00:05:45.790 00:05:45.800 day we'll see you the next time on a
00:05:47.320 00:05:47.330 boiling point

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