Emerson’s boiler-related instrumentation, control, and automation technologies support efficient combustion, maximum steam production, and minimum emissions.
Boilers and other combustion-based equipment are critical to virtually every chemical process and facility. Poor control results in increased fuel costs and emissions, while threatening product quality and throughput across the site, and in the worst case safety issues. Emerson’s automation technologies and combustion process know-how help deliver long-lasting reliability, low costs, and optimal process performance.
Many fuel systems use a volumetric flow meter to monitor the liquid and gaseous fuels feeding burners. This is simple and fully adequate where the type of fuel supply is very consistent. However, if an application is burning opportunity fuels with variable BTU content, maintaining consistent energy flow is more difficult. Emerson’s Micro Motion Coriolis Mass Flow Meters makes fuel control far more self-regulating, since mass flow is closely related to energy content, unlike volumetric flow. Control using mass flow provides more consistent firing, even when energy content varies.
Micro Motion Coriolis Flow and Density Meters
Our Coriolis meters deliver unmatched reliability for mass flow, volume flow & density measurement in your chemical operation.
Fisher 1098 Pressure-Reducing Regulators
Fisher Types 1098-EGR and 1098H-EGR regulators provide economical and accurate pressure control in fuel gas supply to industrial boilers, furnaces, ovens, and mixers.
AMS Device Manager
Predictive maintenance helps plants avoid unplanned shutdowns and inefficient practices that eat away at profits. AMS Device Manager helps avoid these unnecessary costs with a window into the health of intelligent field devices.
Fisher LS200 Series Regulators
Fisher LS200 self-operated regulator are ideal for high-capacity industrial applications such as driers, furnaces, boilers or burners. Ease of maintenance was the primary goal in this product development.
Fisher Digital Isolation Solutions
Take the guesswork out of your safety instrumented system valve assemblies with our proven solutions and expertise.
Fisher Control Valves
Fisher control valves manipulate a flowing fluid (such as gas, steam, water), or chemical compounds to compensate for the load disturbance, and keep the regulated process variable as close as possible to the desired set point.
Valve Fugitive Emissions
The valves in your plant are a leading source of fugitive emissions. Every valve upgrade you make moves you closer to achieving current and future fugitive emission compliance.
DeltaV Safety Instrumented Systems (SIS)
The proven DeltaV SIS continuously monitors your plant’s safety devices’ status and diagnoses the health of the entire safety loop–dramatically reducing your risk.
Water and steam control play very important role in the boiler and are the heart of the steam system. Poor water and steam control can lead to excessive energy loss and potential safety risks. Emerson offers a wide variety of steam and water controls to ensure boilers operate smoothly and efficiently.
Yarway Bottom Blow-off Valves
Rugged section 1 valves to ensure proper bottom blow-off and removal of sludge from boilers. Yarway Bottom Blowoff valves are designed with special geometries and materials to ensure longevity of the valves and superior in-line repairability for ease of maintenance.
Crosby H-Series Direct Spring Safety Valves
Direct spring safety valves that provide comprehensive overpressure protection for ASME Boiler and Pressure Vessel Code Section I, and Section VIII steam safety applications.
Fisher and Sempell Steam Conditioning Valves and Desuperheaters
Improve the thermal efficiency and protect downstream equipment with Fisher and Sempell steam conditioning valves and desuperheaters.
Differential Pressure Flow Measurement in Steam
Accurately measure steam flow to reduce operating costs and project cycle time.
Severe Service Control Valves
Cavitation, flashing, and noise are common challenges experienced when controlling the flow of water and steam. Fisher Severe Service Control Valves provide reliable and accurate flow control while mitigating the negative effects of cavitation, flashing, and noise.
Corrosion Monitoring Technologies for Boilers and Steam Drums
Improve plant uptime and decrease maintenance costs using high quality corrosion data to monitor steam drum integrity.
Bettis XTE3000 Mounted on Yarway Blow-Off and Blowdown Valves
Support safety and reliability requirements with intelligent multi-turn electric actuators. Wireless connectivity supports remote configuration, diagnostics and maintenance.
Yarway Surface Blow-off Valves
Rugged valves to ensure proper surface blow-off and removal of TDS from boilers. Yarway Hy-Drop valves are designed to ensure longevity of the valves and superior in-line repairability for ease of maintenance. These valves are easily set with micrometer or actuator and tapered disc to achieve flow required for removal of suspended solids.
Level Measurement in Steam Drums
Achieve safe and efficient level control in saturated steam applications utilizing dynamic vapor compensation.
Monitoring oxygen content in stack gas is one of the most basic indicators of combustion efficiency. Emerson’s sophisticated stack gas oxygen monitors provide data so operators can determine the proper stoichiometric air flow to match fuel input and optimize combustion.
Rosemount™ 6888 In Situ Oxygen Analyzer
The Rosemount 6888 In Situ Oxygen Analyzer provides a continuous, accurate measurement of oxygen in flue gases coming from any combustion process.
Rosemount™ OCX8800 Oxygen and Combustibles Transmitter
Measure combustion efficiency by monitoring the percentage of oxygen (O2) in flue gas.
AMS Device Manager
Predictive maintenance helps plants avoid unplanned shutdowns and inefficient practices that eat away at profits. AMS Device Manager helps avoid these unnecessary costs with a window into the health of intelligent field devices.
Control Systems and Software for the Chemical Industry
Leveraging DeltaV advanced control systems, chemical producers will achieve higher product quality, more efficient tuning, more refined control, and better process visibility.
In most areas, local environmental regulators require a continuous emissions monitoring system (CEMS) to measure output of regulated emissions, such as unburned fuels, carbon dioxide, carbon monoxide, NOx, SOx, and others. Emerson provides a range of flue gas analyzers that can be matched to the relevant fuel sources and regulatory requirements. These are robust and ready for continuous service, avoiding CEMS outages and related regulatory issues.
Monitor and Report Nitrogen Oxide (NOx) Emissions
Ensure fast and accurate NOx emissions monitoring in industrial combustion plants.
Rosemount XE10 Continuous Emissions Monitoring System (CEMS)
With its built-in performance analytics and automated validation capabilities, the XE10 CEMS ensures accurate emissions monitoring and reporting to help plant operators reduce the risk of non-compliance shutdowns and penalties.
Rosemount CT5100 Continuous Gas Analyzer
Emerson's Rosemount CT5100 Continuous Gas Analyzer is the first hybrid, laser-based analyzer developed for process gas analysis and emissions monitoring.
DeltaV Distributed Control System
The DeltaV DCS is an easy-to-use automation system that simplifies operational complexity and lowers project risk.
Optimizing combustion requires data from multiple sensors, including the flue gas oxygen monitor and CEMS. When all this data is available, it is possible to balance unburned fuel, excess oxygen, and emissions to operate the burner at exactly the most optimized level. Emerson provides these sensors, but also the controller able to make these calculations in real time, to regulate air and fuel flow, delivering the performance required by the application, while minimizing cost.
TopWorx D-Series Discrete Valve Controllers
The D-Series has been built to survive the most demanding applications and conditions, providing reliable service for a lifetime. With its microprocessor-based sensor-communication modules, it delivers position-sensing, bus network communications to facilitate predictive maintenance in On/Off valve applications.
Rosemount XE10 Continuous Emissions Monitoring System (CEMS)
With its built-in performance analytics and automated validation capabilities, the XE10 CEMS ensures accurate emissions monitoring and reporting to help plant operators reduce the risk of non-compliance shutdowns and penalties.
Air and Flue Gas Measurement with Rosemount Annubar Averaging Pitot Tube
A cost-effective, averaging pitot tube flow measurement solution that minimizes permanent pressure loss while delivering advanced capabilities.
DeltaV Safety Instrumented Systems (SIS)
The proven DeltaV SIS continuously monitors your plant’s safety devices’ status and diagnoses the health of the entire safety loop–dramatically reducing your risk.
While a mass flow reading provides a useful picture of fuel energy content, there are some applications where more precise analysis of Wobbe Index, BTU content, and contaminants is required. Emerson offers a variety of gas analyzers designed for combustible and fuel gas measurements, and this data can be used to create a comprehensive picture of the fuel supply and how it will perform in critical applications.
Rosemount XE10 Continuous Emissions Monitoring System (CEMS)
With its built-in performance analytics and automated validation capabilities, the XE10 CEMS ensures accurate emissions monitoring and reporting to help plant operators reduce the risk of non-compliance shutdowns and penalties.
Rosemount CT5100 Continuous Gas Analyzer
Emerson's Rosemount CT5100 Continuous Gas Analyzer is the first hybrid, laser-based analyzer developed for process gas analysis and emissions monitoring.
Control Systems and Software for the Chemical Industry
Leveraging DeltaV advanced control systems, chemical producers will achieve higher product quality, more efficient tuning, more refined control, and better process visibility.
Frequently Asked Questions About Combustion and Boiler Control
While there are highly specialized versions of both types of applications that may act as exceptions, the basics of combustion control in chemical processing facilities are universal. Emerson’s sensors for these applications are not limited to one of the processes or the other.
While hydrogen blending with other fuel gases is still relatively rare, it is likely to grow steadily. So how does it affect instrumentation? On the fuel intake side, hydrogen has lower density than natural gas, but also lower BTU content by volume, so a Coriolis mass flow meter will compensate effectively for the difference to a large extent. Emerson’s Rosemount XEFD gas analyzer can determine the specific hydrogen content, as can a Rosemount Gas Chromatograph. On the stack side, a conventional CEMS can make the required measurements because burning hydrogen creates primarily water vapor, although it does generate NOx, which is probably already being measured.
Some of the oxygen in a stack is stoichiometric oxygen corresponding to any unburned fuel, plus the actual excess amount. Emerson’s Zirconia oxygen analyzer automatically consumes any stoichiometric oxygen present in unburned fuel, so the data it provides reflects only the true excess oxygen level.
