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Common Combustion System Design Mistakes
Using Excess Air
End users are not exclusively at fault for thinking of the introduction of excess air as a quick fix to provide for uniformity and turn-down. Many a lazily-constructed combustion system has been run with excess air as a way to mask its inadequacies, though this practice only highlights them, as the necessity of running excess air is a hallmark of poor planning.
What might seem like a nice solution will lead to greater problems down the road. When excess air is used as a method of turn-down, your burners aren't operating efficiently because they're burning the same amount of fuel to create a lower-temperature environment. Efficiency is further compromised if you're running those burners at lower fire as well, since most are designed to run best at their high-fire settings. Not only that, but using excess air leads to poor combustion, wherein the products of combustion don't mix properly.
Still, at Thermal Products & Solutions we understand that some systems must use excess air to achieve the preferred environment, but these are the exceptions. When a combustion system is designed with the application in mind, the introduction of excess air is often unnecessary.