Gas emission analysis for boiler performance otimization

Gas emission analysis for boiler performance optimization

According to the newspaper O Globo (2021), 86% of carbon dioxide emissions come from the burning of fossil fuels for the production of energy and materials. Despite the alarming number, 27% of Brazilian industries have already commitmented to carbon neutrality, with targets to reduce carbon emissions. This change in attitude reflects positively in several ways, especially by increasing productivity and quality of the product produced. In addition to the operational benefits, this concern also addreses ESG issues, helping the industry to adapt to the standards required by government agencies.

The industry uses gases in various stages of the production process, particularly in the operation of boilers. This type of equipment transforms the energy of the fuel into thermal energy, heating the water in its tanks and producing steam. This steam is used in various industrial processes, such as heating and pasteurization, in dairy factories. To meet such demand, there are different types of industrial boilers, such as:

Fire Tubes: These are characterized by a configuration in which the emitted gases pass through the tubes, while the water stays in tubes. They are ideal for steam generation up to 30 tons/h and are known for their quick adaptability to changing steam demand. They are also able to use various types of fuels, including biomass;
Water tubes: In this case, the water circulates inside the pipes, while the gases resulting from combustion are outside. They are also used for the generation of electricity, due to their ability to withstand high pressure and generate large amounts of steam.
Heat recovery: They are designed to harness waste heat from industrial processes such as turbines, motors, and furnaces. This heat generates steam, which can be applied in industrial heating, for example.

How gas emissions impact the production process

As previously mentioned, the boiler is an equipment present in almost all sectors of the manufacturing industry. Due to its intense use, its focus is on improving the efficiency of boilers by using renewable fuel sources, such as biomass. These sources emit fewer greenhouse gases and reduce the carbon footprint in industries. Additionally, they have greater availability and low cost, as agricultural waste is generated naturally as part of the production process.

Reducing gas emissions is indispensable, as they impact products in different ways, such as:

Food industry: Here, the quality of the steam generated by the boiler is essential. Contaminant gases such as nitrogen (N) and sulfur dioxide (SO2) affect the purity of the steam, compromising the safety and quality of processed foods;
Beverage industry: Contaminants can change the taste and quality of beverages, as well as fail to meet food safety standards;
Textile sector: In dyeing processes of fabrics, the gases emitted can cause stains or unwanted changes in colors;
Pulp and Paper: They influence the efficiency of the drying process and the final quality of the paper;
Chemical: The presence of polluting gases interferes with chemical reactions, resulting in low-quality or even dangerous products;
Pharmaceutical: Sterilization of equipment and drug production require pure steam. Contaminant gases can even affect the effectiveness of medications;
Metals industry: Acidic gases such as sulfur dioxide (SO2) cause corrosion of metal equipment and affect the purity of metals during smelting;

How is the analysis of gas emissions in a boiler carried out?

Due to its influence on both productivity and product quality, industries seek to accurately measure quantities and types of gases emitted by boilers. To do this, the first step is the installation of gas analyzers, with infrared (IR) and mass spectrometry (SM) being the most commonly used. After that, technologies such as ST-One® Hardware read these sensors and store the collected information in a database. By measuring the composition of the gases in real time, it is possible to explore data analysis and gain new insights to improve the performance of the boilers. The last step is to make the necessary adjustments to the boilers.

Each type of gas identified during the operation of the boiler indicates something about the production process. Inadequate oxygen (O2) levels help determine if there is excess or lack of air in combustion or problems in the fuel-air mixture. Carbon dioxide (CO2) is related to the amount of fuel burned, high levels of this gas indicate that the burning was complete. Carbon monoxide (CO) indicates the efficiency of production, as this is a dangerous by-product of incomplete combustion. Nitrogen oxides (NOX) are significant pollutants, so their measurement is important for assessing environmental impact. Finally, sulfur dioxide (SO2) is relevant in boilers that use fossil fuels, its high presence indicates the use of low-quality fuel.

The impact of each greenhouse gas is measured through the Global Warming Potential (GWP). It compares the heat-holding capacity of a gas to carbon dioxide for a specific period. In industries, this falls into three categories: Scope 1 (produced directly by the company), Scope 2 (generated by energy and other resources), Scope 3 (resulting from indirect sources in the supply chain).

Types of boiler gas emission analysis

Data collection focused on the emission of gases in a boiler allows for various types of analysis, such as:

Energy efficiency: It can be done in two ways: (I) The direct method accounts for the energy flows entering and leaving the boiler, based on the formula Efficiency = (Total Energy Supplied / Useful Energy Produced) X 100. The (II) indirect method (or “loss” method) calculates the efficiency considering all energy losses, such as heat lost by exhaust gases, radiation losses, etc. Its formula involves all losses to determine the actual efficiency.
Predictive maintenance: Scheduled maintenance, without hindering the flow of the production line. This is due to the analysis of the main indicators of the boiler. For example, if there is an increase in CO levels, this analysis can investigate whether this is due to incomplete combustion or a problem with the air supply;
Compliance analysis: compares emission data with regulatory limits to ensure that the operation is within legal standards. This avoids fines and contributes to sustainable development;
Exhaust Gas Analysis: Measures the composition of exhaust gases to detect levels of pollutants. It helps identify combustion problems and the need for adjustments or maintenance.
Combustion analysis: Monitors combustion efficiency and identifies the presence of polluting gases such as CO and NOX. Allows adjustments in the air-fuel ratio, flame temperature control, among others;
Thermography: Detects hot spots or may indicate insulation problems or inefficient heat transfers. This results in improvements in insulation, which reduces the amount of fuel and, consequently, the emission of gases.

Why should the manufacturing industry monitor gas emissions?

One of the biggest benefits of gas emission analysis is increased productivity. This is because it is possible to use only the necessary amount of fuel for combustion, make adjustments to the machinery and increase the quality of the steam produced.

In addition to the operational issue, the industry’s concern also lies in ESG issues. In 1994, United Nations Framework Convention On Climate Change established targets to stabilize the concentration of greenhouse gases in the world. The purpose of this action was to reduce climate change, which led to the creation of the Greenhouse Gas (GHG) Emissions Inventory. This inventory collects direct and indirect emission data, as well as efforts to balance production. It helps inform decision-making about GHG use, identify future trends and opportunities, and is mandatory.

Ideally, this document should be prepared annually by the manufacturing industry. Additionally, it must follow the standards set by the GHG Protocol. The steps that must be followed to prepare this inventory are:

Define boundaries: this is divided into organizational (delimitation of sectors and subsidiaries included in the document) and operational (activities, processes, and services).
Define scopes: categorized between Scope 1, 2, and 3, as explained earlier.
Define the period: this usually encompasses 1 year of operation, but can be divided into smaller periods, such as quarters and semesters.
Collect information: map the available information to calculate emissions, which can be done with the help of disruptive technologies such as the ST-One™ Solution.
Define the next steps: it is important to plan actions based on the results found. An example of this is the redefinition of strategies, such as the implementation of a new waste disposal stream;

Data science and the reduction of greenhouse gases

According to the Boston Consulting Group (2023), the use of Data Science has the potential to avoid the emission of 2.6 to 5.3 gigatons of CO2. In a global context, this represents a reduction of 5% to 10% of the emissions foreseen by the Paris Agreement.

In addition, it is an important ally for aspects related to ESG (Environmental, Social and Governance). In the environmental part, besides reducing polluting gases, optimizes the use of natural resources, such as water and energy. It also assists in the implementation of reverse logistics systems, facilitating the reuse of materials and impacting cost reduction.

On the social side, the use of this technology to reduce pollutants improves the health and safety of employees and communities near the factories. This demonstrates a commitment to social welfare.

Finally, in governance, emissions monitoring demonstrates transparency, which improves the industry’s reputation and increases investor confidence. Additionally, it is capable of identifying operational risks.

In short, boiler emission analysis is beneficial to industries in many ways. Data science allows you to identify the different gases produced and the analysis of their levels to discover points of improvement in the boiler. From this, the industry can act to increase productivity, in addition to complying with environmental protection laws. Learn more about us.