Objective 4:Optimize
fuel efficiency and
reduce emissions
Facilitator: Boniface MUKESHIMANA:
MAPPM, Bsc. With Education, PREMA International Certified.
Contact: Tel: +250788501605
Email: bmukesha@gmail.com
I. ✅ Key Objectives
Lower fuel consumption
Reduce CO₂, NOₓ, SOₓ, CO, and particulate emissions
Improve combustion efficiency
Extend equipment lifespan
II. Optimization Strategies
1. Air-Fuel Ratio Control (AFR)
Goal: Ensure complete combustion with minimal excess air.
Use O₂ trim systems to continuously monitor and adjust oxygen levels.
Target 2–3% excess oxygen in flue gas (varies by fuel type).
Avoid too much excess air, which cools the flame and wastes energy.
2. Upgrade to Low-NOx Burners
Install low-NOx or ultra-low-NOx burners to minimize nitrogen oxide formation.
Utilize staged combustion and flue gas recirculation (FGR).
3. Implement Combustion Controls
Use a Burner Management System (BMS) integrated with Programmable Logic
Controller PLC/SCADA.
Employ flame sensors, actuators, and variable speed drives (VSDs) for
fans/blowers.
Implement real-time monitoring and auto-tuning algorithms.
4. Heat Recovery
Install Economizers: recover heat from flue gas to preheat feed-water or
combustion air.
Consider air preheaters, condensing economizers, or waste heat boilers.
5. Fuel Quality Management
Use high-quality, clean fuels with low moisture and sulfur content.
Ensure consistent fuel pressure, flow, and atomization (for oil burners).
6. Regular Preventive Maintenance
Clean burners, flame sensors, and nozzles regularly.
Inspect for leaks, corrosion, and soot buildup in combustion chamber and
flue.
Calibrate sensors (O₂, CO, temperature) to maintain control accuracy.
7. Insulation & Duct Sealing
Insulate combustion chambers, piping, and ducts to prevent heat loss.
Seal all leaks in ducts and chimneys to maintain draft and prevent oxygen
ingress.
8. Monitor Emissions and Stack Losses
Use a Continuous Emissions Monitoring System (CEMS).
Analyze stack gases (O₂, CO, NOx, SOx, etc.).
Calculate stack loss and use it to optimize combustion settings.
III. Key Performance Indicators (KPIs)
IV. Advanced Options
Digital Twin or AI Optimization: Use software simulations and AI to predict and
optimize burner operation.
Alternative Fuels: Explore biogas, syngas, or hydrogen blends if viable.
Carbon Capture Readiness: Prepare for future carbon reduction regulations.
V. Summary Checklist
