At the same time, the remaining char continues to burn in the primary zone. Both processes release energy. These zones often operate simultaneously when unburned pellets are introduced into the system. Effective mixing of secondary air with the flue gases is essential for complete combustion, and this is achieved through precise air dosing. The longer the flue gas remains in the furnace, the more complete the combustion.
The amount of excess air in the secondary zone is a key factor in controlling emissions of carbon monoxide (CO) and unburned hydrocarbons (OGC). However, a tradeoff exists. If the air supply is too low, CO and OGC emissions increase, although nitrogen oxide (NOx) emissions stay relatively low. With greater excess air, CO and OGC decrease, but NOx emissions rise. Research has shown that biomass burners often emit two to four times more NOx than oil burners.
Many biomass boilers and burners that lack electronically controlled combustion systems are designed to operate with high excess air. More precise air management, using variable-speed fans controlled by CO or Lambda sensors, can significantly reduce emissions. Biomass boilers equipped with Lambda control are considered state-of-the-art, but many systems still only allow for manual adjustments.
Two other important parameters influencing emissions are residence time and combustion temperature. A high temperature and extended residence time can reduce CO and OGC emissions to near zero. However, NOx levels tend to increase with temperature unless the residence time is sufficient.
Therefore, air staging, which ensures high temperatures and long gas retention times, is an effective method for reducing emissions in pellet boilers.