Optimize Air to Fuel Ratio for Process Efficiency
One of the most important ways to reduce energy consumption in a manufacturing environment is to optimize the combustion control on industrial boilers, steam generators, and process heaters. By monitoring the air and fuel rates to burners, optimal air to fuel ratios is achieved. This results in significant reductions in energy costs of natural gas (or propane), and improves process efficiency, as well as product quality and yields.
Environmental Regulation and ISO 50001
As part of an overall strategy to reduce plant-wide emissions, many local and state-wide jurisdictions have environmental regulations requiring flow meters on all medium and large size heating units. By tuning burners to reduce excess fuel usage, emissions are reduced and energy is saved. In addition, the newly promulgated ISO 50001 standards define the best practice for energy management, and fuel line monitoring will play a big role. Common applications for fuel line flow monitoring will be found in a variety of industries including Textile, Glass Manufacturing, Automotive, Aluminum & Steel, Food & Beverage, Pulp & Paper, Power, Chemical, and Refining.
Thermal Flow Meters
Thermal mass flow meters are ideal instruments for this application. The Sage Prime provides both easy-to-install insertion thermal mass flow meters as well as in-line thermal flow meters, with built-in flow conditioners that monitor the air and fuel flow rates to the burner. These direct mass flow meters do not require separate temperature or pressure transmitters, have no moving parts, are highly accurate and repeatable, and have negligible pressure drop. The Sage Thermal Mass Meters have extraordinary rangeability of at least 100 to 1, as well as fast response. In addition to the 4 – 20 mA control output of flow rate, the meters also provide pulsed outputs of consumption, in conjunction with fully Modbus compliant RS485 RTU communications. The meters also feature bright graphical displays of flow rate, a non- resettable totalizer (often a requirement for environmental reporting), a temperature reading, plus, continuous diagnostics. For difficult to reach burner lines, or for locations with extreme radiant heat, Sage also offers a remote style flow meter, with up to 1000 feet of lead length compensated cable – all electronics and powering are done at the transmitter – thus, the probe or flow body simply has a terminal junction box.