The Importance of Combustion Control in an Industrial Setting

Combustion Control boiler all set up

Today, industrial facilities have to navigate a world of safety regulations, guidelines, and the need for efficiency and performance. We work with all components used in industrial settings from boiler repair to welding to mechanical repair or pressure piping. We understand the difficulty many industries face. In previous posts, we’ve discussed the history of combustion and the combustion engine before and how it plays a role in various industrial applications. In an industrial setting, combustion control is necessary to ensure optimal operation and safety, pollution control, and operation efficiency. 

Why Combustion Control is Necessary for Optimal Performance 

Newer industrial boilers are equipped with more sophisticated combustion control systems that allow for the regulation of carbon monoxide and nitrogen oxide emissions monitoring. The Department of Energy has energy goals when it comes to various sectors and industries and their use of energy and environmental impact. According to some government estimates, over 45,000 industrial and commercial boilers are larger than 10MMBtu with a total fuel input capacity of 2.7 million MMBtu/hr. And according to the Office of Energy Efficiency & Renewable Energy, boiler efficiency can be improved in three ways: 

  • Replacing with new boilers
  • Replacement of the burner 
  • Installing a combustion control system 

What Does a Newer Combustion Control System Do?

Burners are an essential component of many industrial applications. Gas and oil burners are responsible for powering package boilers, furnaces, and other heat processes. Newer combustion control systems and their respective gas sensors set the opening of fuel and air inlets. The system is constantly providing feedback and measurements of oxygen, carbon monoxide, and nitrogen oxide concentrations. 

Improving Efficiency for Industrial Boilers 

Effective combustion control and monitoring systems will improve the overall efficiency of an industrial boiler. The idea is that combustion efficiency is achieved through a burner’s ability to burn fuel, as measured by unburned fuel and excess oxygen in the exhaust. These systems tend to be digitally controlled and are capable of monitoring a boiler system’s efficiency. These systems will also monitor boiler performance, reduce greenhouse gas emissions, and improve fuel efficiency. 

As defined by the United States Department of Energy, Combustion efficiency is a measure of how effectively the heat content of a fuel is transferred into usable heat. Key indicators of combustion efficiency are the stack temperature and flue gas oxygen concentrations.

A Quick Example of Boiler Efficiency and Energy Usage 

As published by the U.S. Department of Energy, if a boiler operates for 8,000 hours per year and consumes about 500,000 million MMBtu of natural gas produces about 45,000 lb/hour of 150-PSIG steam. The stack gas measurements will be 44.9% with a flue gas air temperature of 400 degrees. From this equation, the combustion efficiency can be measured at 78.2%. Improving the efficiency that reduces the excess air even by 9.5% with a temperature of 300 degrees, the efficiency increases to 83.1% with annual fuel costs of about $235,856. The difference is substantial and why efficiency matters for energy use consumption.

The Stoichiometric Balance – Finding the Right Ratio 

Finding the right amount of air for the operation allows for the perfect balance that achieves optimal efficiency. A stoichiometric chemical equation is essentially balanced. The equation for combustion will usually involve Co2 and H2O from the reaction of another chemical and oxygen O2. Combustion conditions are never in perfect harmony, but any excess air must be used up to burn the fuel. This is called a stoichiometric amount of air. To ensure that the fuel will be used up, there is excess air. This air increases the amount of oxygen to the combustion. Stoichiometry involves using relationships between reactants or products in a chemical reaction to find precise results or data. 

The Benefits of Combustion Control Systems 

As combustion control systems become more commonplace and accessible, they are making it easier for industry levels to ensure that their systems are working at an optimal level. The main benefit of a combustion control system is the overall energy savings. The gain inefficiency is a result of a reduction of oxygen used. Other benefits include: 

  • Carbon monoxide monitoring checks for potentially unsafe or inefficient combustion does not happen 
  • Very low levels of oxygen in the exhaust flue gas improve efficiency 
  • Real-time data and boiler performance 
  • A control system that monitors gases and helps avoid accidents 
  • It prevents unsafe conditions from happening 

Get Combustion Control for Your Industrial Boiler or Application

When it comes to industrial boilers or equipment, Wyler Industrial has you covered. We offer combustion control services to help you achieve boiler efficiency and optimal performance. We ensure your equipment is working like it’s supposed to, not only for safety but for efficiency. 

Ready to see the efficiency potential of your boiler with combustion control? Call Wyler Industrial today and learn more. 


Boiler Disasters: What Can Go Wrong if You Don’t Hire Professional Help

We all love our boilers, even if you don’t fully understand what they do. Boilers are especially pertinent during the winter months. They stop your home’s pipes from freezing, after all! It’s easy to take boilers for granted. The moment these pieces of equipment cease to work, it’s as if the entire world stops. And what are you to do? Before you go fetch the toolbox, remember that boilers are complex and require professional maintenance in order to avoid any issues. If you’re ready for high-quality service, choose Wyler Industrial. In the meantime, take a look at these common nightmare scenarios that may have occurred if you decided to fix your boiler on your own.

Annual Tune-Ups and Inspections are a Must

In order to avoid expensive repairs in the future, make sure your boiler is inspected and tuned up by a professional once per year. Through regular inspections, your boiler will be able to receive any repairs it may need now rather than having to repair or replace a more substantial aspect (or the entire boiler itself) in the near future. By preparing preemptively to face any repair or mishap, you won’t have to suffer in the cold winter months or pay exorbitant amounts of money when the time for maintenance comes around. If large-scale repairs are necessary, don’t put them off! Taking care of boiler repair can cost a pretty penny but if you put it off, it’ll be much pricier in the future. Avoid any future complications and have your boiler taken care of, today.

Choose a Reputable Team to Take Care of Your Boiler

Your boiler deserves the best help it can get. Don’t cut corners when it comes to boiler repair. Instead, make sure to hire a team who understands boilers, inside and out. With Wyler Industrial’s help, your boiler will be up and running in no time. We’ve been serving the El Paso area for decades and decades. Throughout our time, we’ve seen every single boiler issue imaginable and we’ve been able to use this knowledge and expertise to fix whatever may be ailing your unit. Give us a call today to learn more about what we can do for you. Sure, winter might’ve just ended but that doesn’t mean your boiler should be forgotten about until next October. We’re ready to help!

Famous Boilers from Popular Culture

boilerWhether you have a boiler or furnace, you know how important each unit is for keeping your home nice and toasty during the winter. While a furnace heats your home using air, a boiler uses water to do so. Depending on the age, type, and size of the structure you are trying to heat, you may have either a boiler or a furnace. If you have a boiler, you know just how hot it can get. In fact, this fact along with having boilers in general, has appeared in many different forms of popular culture, from books and movies to video games and tv shows. Here are a few of our favorites.

#1: The Shining’s Infamous Boiler

Probably the most famous boiler from pop culture history is the one from The Shining by Stephen King. Now, for anyone who has only seen the movie but not read the book, there are some serious spoilers up ahead. This is because the movie’s ending was changed significantly from the ending of the book. At the end of the book, rather than freezing to death in the snow, Jack Torrance is killed when the infamous boiler from the beginning of the book explodes. As part of his job, Jack was supposed to relieve the pressure from the massive, old-timey boiler but had neglected to do so their entire stay at the overlook, causing it to explode at the end. All work and no play really does make a Jack a dull boy.

#2: Marshall’s First Boiler on How I Met Your Mother

When Marshall and Lily move into their first home in season 7 of How I Met Your Mother, they’re a bit lost at typical home stuff, like using a breaker or living with a boiler. When searching for the breaker in the basement after the electricity goes out, Marshall is advised to spit on the boiler to hear it sizzle so he knew where it was in order to not burn himself on it. While we don’t see the boiler, its presence is known.

#3: The Boiler Room in Resident Evil 2

While the boiler itself doesn’t come into play much, the boiler room is an important place if you’re trying to beat the Resident Evil 2 video game. You probably remember it as one of the rooms zombies break into but later on, you have to use the door they came in through as an exit. According to Jeffrey Parkin of Polygon, there’s gunpowder and other supplies in there, so be sure to look around!

Boiler Repair and Installation

Aside from appearing in movies, TV shows, video games, and other popular culture, these three boilers have another thing in common: they probably need boiler repair from time to time (yes, even the one in the video game). Boilers can break down for a number of reasons and sometimes, they just give out altogether. Whether they were in need of a repair or a new boiler installation, a professional would’ve been needed to get the job done. In their worlds, they didn’t have Wyler Industrial to rely on. Thankfully, we exist in real life.

Boiler Services from Wyler Industrial

If you’re in need of boiler repair and installation, look no further than Wyler Industrial. We have served businesses in El Paso and throughout the southwest, and are ready and able to help you. We offer high-quality and dependable boiler services that can get your current boiler up and running or your new boiler installed in no time. Call us today so we can get started!