In today’s world, energy conservation reducing environmental pollution are top priorities across various industrial sectors. Burners, as the central components of industrial furnaces and boilers, are among the most energy-consuming devices in residential, commercial, and industrial applications. To achieve optimal performance and cost-efficiency, burners must be precisely controlled and continuously optimized. With the aid of smart technologies, it is possible to enhance burner efficiency, lower fuel consumption, and reduce harmful emissions. This study focuses on smart burner systems and their role in improving safety, efficiency, and reducing operational costs.
Smart Combustion Control and Continuous Monitoring of Combustion Parameters
Smart systems for industrial burners use sensors and advanced algorithms to continuously monitor and regulate critical combustion parameters such as temperature, pressure, fuel-to-air ratio, and exhaust gas composition. This technology aims to optimize burner performance by increasing energy efficiency, reducing fuel consumption, and minimizing emissions.
However, to benefit from intelligent burner systems, it is necessary for the burner to support modulating operation. Modulating burners can operate continuously within a defined capacity range without sudden variations. This characteristic allows the smart controller to regulate fuel and air dampers based on process needs and control the flame effectively. In other words, a modulating burner must have a proper turndown ratio to sustain optimal efficiency and stable combustion across its entire operating range.
In such modulating burners, as part of industrial burner automation, the intelligent controller automatically adjusts the fuel and air dampers in response to deviations from the set point. For instance, in an industrial boiler, if temperature or pressure falls below the predetermined value, the smart controller commands an increase in the fuel and air, increasing flame intensity and bringing the process back to the set point.
On the other hand, if temperature or pressure rises above the desired level, the controller automatically sends control signals to the actuators to decrease the fuel and air flow, thereby lowering the flame and sustaining optimal operating conditions.
To automatically adjust the fuel and air flow of modulating burners and control the flame according to system demands, three control methods are available, which are briefly presented below.
Mechanical Modulating Burners: In these burners, the fuel/air ratio are adjusted through mechanical linkages and cams. Over time, due to mechanical tolerance and the accumulation of dust and debris, the initial burner settings may become disrupted, requiring readjustment.
Pneumatic Modulating Burners: In these burners, a proportional gas valve adjusts both the gas and air ratio simultaneously. However, accurate control of the air/gas ratio across the range from minimum to maximum capacity is not possible.
Electronic Modulating Burners: In these burners, a smart controller works alongside two or more independent actuators for air, fuel, or other removable components of the burner. The system adjusts fuel and air ratio in accordance with furnace load, providing much higher accuracy than mechanical and pneumatic methods, and avoiding the common errors associated with them.
Capabilities of Smart Electronic Modulating Burners
Given the operational limitations and errors in mechanical and pneumatic modulating burners, this generation of burners has been progressively replaced by electronic modulating burners. Industrial burner automation through these smart and modulating electronic burners marks a significant step forward in the advancement of heating technologies. These devices are regarded as some of the most advanced technologies in the heating industry, enhancing burner performance through a sophisticated central processor.
These systems increase energy efficiency, lower operational costs, and improve the performance of thermal systems by continuously monitoring combustion parameters and automatically adjusting the fuel/ air ratio. These burners automatically adjust their settings based on changes in process conditions, which helps minimize energy waste in the boiler and furnace while reducing the frequency of on/off cycles. This functionality leads to a significant improvement in the overall efficiency of heating systems.
1- Support for Advanced Automatic Control Algorithms: Smart burners can automatically optimize their settings using advanced control algorithms like PID, based on environmental conditions and process requirements. This capability allows the burner performance to consistently adapt to system variations, ensuring optimal energy usage.
2- Using Independent Actuators in Air Damper and Fuel Valves for Precise Fuel and Air Flow Control:
This feature allows the burner to adjust fuel and air flows independently, providing precise control according to the system’s needs under different conditions. Such adjustments enable dynamic and efficient combustion, preventing energy loss.
3- Continuous Monitoring of Fuel and Air Pressure: While pressure switches for air and gas are typically used in all burners, certain systems, like AutoFlame, are equipped with advanced fuel and air pressure sensors that are continuously monitored. This precise monitoring ensures that any fluctuation in pressure is immediately detected, and necessary actions are taken to maintain burner efficiency.
4- Removing the Mechanical Linkages and Minimizing Adjustment Errors: By replacing traditional mechanical systems with electronic technologies, smart burners can make more precise adjustments with improved tolerance. This reduction in mechanical errors increases accuracy and decreases the need for manual adjustments.
5- Intelligent Fault Detection and Error Code Provision for Simple Troubleshooting: Smart systems can identify faults and send error codes to operators. This capability facilitates easier fault detection and repair, reducing downtime to a minimum.
6- Fuel/Air Ratio Optimization and Efficiency Enhancement: With precise monitoring and adjustment of the fuel-to-air ratio, electronic modulating burners are able to maintain stable and optimal combustion. This process enhances combustion efficiency and minimizes emissions resulting from incomplete fuel combustion.
7- Optimizing Efficiency by Reducing Excess Air with Carbon Monoxide and Oxygen Sensors: Using high-precision sensors for monitoring CO and O₂ levels enables accurate control of excess air, minimizing energy waste and improving overall system efficiency.
8- Ability to Monitor Combustion products: Equipped with advanced online monitoring systems, smart electronic modulating burners can accurately measure exhaust oxygen, carbon dioxide, carbon monoxide, and other combustion pollutants. This functionality allows for continuous self-regulation and performance optimization, ensuring compliance with environmental regulations and minimizing harmful pollutant emissions.
9- Lower Maintenance and Servicing Costs: By enhancing operational efficiency and minimizing equipment failures, smart burners simplify maintenance processes and significantly reduce overall maintenance and repair costs.
10- Improving Safety and Reducing Hazards: With advanced protection systems and precise monitoring of burner performance, risks associated with temperature, pressure, and fuel fluctuations are minimized. These features contribute to increased safety in industrial environments.
11- Ability to Connect to the PLC Management System in the Factory: Smart burners are capable of direct integration with PLC (Programmable Logic Controller) systems. This enables centralized supervision and control of burner operations and production workflows, improving system reliability, operational efficiency, and energy resource management.
12- Integration with Building Management Systems (BMS): These burners can interface with the Building Management System (BMS), enabling centralized interaction with other building systems and ensuring efficient operation of heating and energy infrastructures.
13- Reducing Frequency of Burner On/Off Cycles: Smart burners, through modulating control, are capable of operating continuously over a wide capacity range. This feature reduces the frequent on/off cycling of the burner, minimizing boiler or furnace chiller losses. As a result, this enhances system efficiency, minimizes thermal stresses in the furnace, and reduces the risk of failure in the burner’s electronic components.
Main Components of the Control System in Electronic Modulating Burners
Smart electronic control systems for industrial burners, as part of the industrial burner automation process, consist of several key components, each working independently to automatically and optimally control the burner’s performance. The main components of this system include the processing and actuator control unit, sensors, the fuel train connection system, and user interfaces, all of which work in coordination to enhance the burner’s efficiency.
The following sections explore these components in detail. In the figure below, a diagram illustrating the operational layout of raadman electronic modulating burners is presented. This diagram displays all the components utilized in a smart, modulating burner, exemplifying the smartification of industrial burners.
Central Processing Unit (CPU) or Controller
This unit is responsible for processing the data received from upstream control systems such as PLCs and sensors, and implementing the necessary adjustments. It plays a central role in optimizing burner performance, making intelligent decisions for various settings. The controller receives all data related to actuators, sensors, user interfaces, switches in the fuel, air, and flue gas paths, as well as the flame detection system. After analyzing and processing the input data, while ensuring safety protocols, the controller sends the required information to actuators, VSDs, and other burner control components.
Within the field of smart controller manufacturers, apart from product updates, safety and ensuring dependable operation are critically important, as errors in controllers can sometimes lead to irreparable consequences. AutoFlame, a UK-based company, manufactures products with a very low error margin and a SIL3 rating, making them a reliable choice for industrial applications.
The fully intelligent AutoFlame controller serves as a central control system that helps optimize energy consumption, increase safety, and reduce emissions by automatically adjusting parameters like the fuel-to-air ratio, temperature, and pressure. Since this system provides centralized monitoring and control, its use in raadman burners ensures precise, safe, and cost-effective performance.
Actuators
Actuators are devices that function based on commands from the central processing unit. They precisely control the flow of fuel or air into the burner and are also used to adjust the positions of removable components within the burner. It is important to note that high-capacity burners rely on these removable components to achieve high conversion ratios. To maintain the required accuracy and stability in adjustments, advanced actuators are essential. AutoFlame actuators are certified to meet the latest global standards and hazardous area regulations. They accurately regulate the fuel and air flow across all burner capacities, ensuring optimal adjustments are made according to the ideal fuel/air ratio curve.
Sensors
Sensors play an essential role in monitoring the combustion process. For instance, temperature sensors measure the exhaust gas temperature from the furnace or boiler, helping prevent temperature changes that might result in incomplete combustion or equipment damage. Pressure sensors monitor the fuel and air pressures, halting any unauthorized fluctuations. Moreover, combustion gas sensors measure the composition of combustion products like CO2, O2, and CO to ensure that combustion occurs efficiently and completely. These sensors, by sending information to the central processor, can also automatically reduce excess combustion air, which ultimately improves the system efficiency.
User Interfaces
These interfaces enable users to view the operational status of burner and apply the required adjustments. Additionally, this component informs operators about the necessary steps to take in the event of malfunctions or the need for recalibration.
AutoFlame user interface is one of the most advanced burner control and management interfaces available. With its intuitive design and digital display, it provides operators with the ability to monitor and adjust combustion parameters accurately.
Advantages of Using Smart Controller in Industrial Burners
Using smart controller in electronic modulating burners, as part of the industrial burner automation process, provides various advantages, having a substantial impact on energy efficiency, pollutant reduction, safety enhancement, and operational cost reduction. This intelligent system implemented in industrial burners optimizes fuel consumption and reduces maintenance costs by continuously monitoring the burner’s performance and automatically adjusting combustion parameters. Furthermore, smart control significantly contributes to lowering environmental pollutant emissions and improving equipment safety.
The diagram below compares the efficiency of a modulating boiler at various partial loads with that of a single-stage burner boiler. As shown in the diagram, the efficiency difference between these two types of boilers increases at lower loads. Since the boiler typically operates at partial loads, this discrepancy leads to a substantial difference in the overall efficiency of boilers with modulating versus non-modulating burners.
In addition to enhancing the efficiency of combustion systems with electronic modulating burners, the service life of burner components is extended due to industrial burner automation. The reduction in the frequency of start-stop cycles and thermal stresses in the combustion series results in less wear on equipment. Furthermore, in the furnace, due to the decrease in thermal fluctuations, thermal stresses are reduced, leading to an increase in the lifespan of the furnace and combustion chamber.
The Effects of Combustion Automation on Improving Industrial Burner Performance
With the advancement of modern technologies, burner automation has revolutionized their performance. Burner automation has significantly enhanced burner efficiency, leading to reduced energy consumption, improved productivity, and lower operational costs. These technologies facilitate optimal management of the combustion process and enable intelligent remote monitoring, allowing burner systems to adapt to changing environmental conditions and continuously optimize performance.
AutoFlame has taken a significant step in industrial burner automation and remote control of burners and boiler rooms. Advanced models like the MK8 DTI are capable of connecting to Building Management Systems (BMS), facilitating remote monitoring and control of burners and boilers through the network. This feature allows operators to monitor system performance in real-time and make necessary adjustments when needed.
In response to the growing need for energy efficiency and improved performance in industries, raadman burners can easily integrate with smart systems like AutoFlame. This collaboration drives industrial burner automation, allowing them to automatically optimize their performance based on environmental conditions and system demands, ultimately enhancing efficiency. The implementation of these technologies in raadman industrial burners marks a significant step toward greater operational efficiency and reduced costs.
