Print this page Improving Energy Efficiency of Boiler Systems
A. Bhatia, B.E.
Course Outline
A boiler installation
costing $75,000 can easily consume over $400,000 in fuel every year. Consequently,
even with very economical fuel costs, a difference of just a few percentage
points in boiler efficiency can translate into substantial savings. Understanding
boiler operating costs is the key to maximizing investments year in and year
out.
This 4-hour course provides an overview of the key measures, which can be readily
followed and implemented to improve efficiency, save money and limit environmental
impacts.
This course
includes a multiple-choice quiz at the end, which is designed to enhance the
understanding of the course materials.
Learning Objective
At the conclusion of this course, the student will be aware of:
- Direct and indirect method for evaluating boiler efficiencies
- Establishing list of energy losses in a boiler system
- Combustion analysis; Excess air control and Air-Fuel mix
- Heat recovery systems (economizers, preheater, flue gas condensing etc)
- Waterside and fireside problems
- Boiler water treatment approaches
- Importance of condensate recovery
- Blowdown optimization and waste heat recovery using flash tanks/ heat exchangers
- Energy efficiency in steam distribution
- Energy efficiency in steam utilization
- Automation using burner controls and oxygen trims
- Boiler audit
checkpoints & questionnaire
This course is aimed at students, professional engineers, boiler operators, energy auditors, O & M personnel, environment and loss prevention engineers.
Course Introduction
The factory efficiency
of your boiler system is useful only if it is repeatable and sustainable over
the life of the equipment. The very purpose of generating steam at the highest
thermal efficiency is lost, if the steam is subsequently wasted through improper
distribution or utilization. In fact, the majority of the improvement is after
the steam is generated - in the distribution & utilization.
The energy conservation opportunities are wide spread, some are a matter of
regular maintenance; others are considered when a major upgrade is required.
In small boilers the fuel saving opportunities could be attained by simple monitoring
and tune-ups, in heavy commercial and industrial boiler applications these efficiencies
are normally found in waste heat recovery systems, process automation, and improved
operating practices.
This course attempts to provide simple facts and energy efficiency opportunities
in the areas of combustion management, makeup & feedwater management, condensate
return, blowdown system, waste heat recovery and steam distribution & utilization.
Course Content
The course content is in a PDF file Improving Energy Efficiency of Boiler Systems . You need to open or download this document to study this course.
Course Summary
The performance
parameters of boiler, like efficiency and evaporation ratio reduces with time
due to poor combustion, heat transfer surface fouling and poor operation and
maintenance. Even for a new boiler, reasons such as deteriorating fuel quality,
water quality etc. can result in poor boiler performance. Boiler efficiency
tests help us to find out the deviation of boiler efficiency from the best efficiency
and target problem area for corrective action.
Flue gas temperature, oxygen and carbon dioxide measurements are good indicators
of the excess air level and boiler efficiency changes. Larger the excess air
and the flue gas temperature, larger shall be the losses. An often stated rule
of thumb is that boiler efficiency can be increased by 1% for each 15% reduction
in excess air or 40°F reduction in stack gas temperature.
The boiler water must be sufficiently free of deposit forming solids to allow
rapid and efficient heat transfer and it must not be corrosive to the boiler
metal. Deposits in boilers may result from hardness contamination of makeup
water and corrosion products from the condensate and feed water system.
The heat recovery from flue gases and boiler blowdown provides another means
of tapping energy. The payback period varies from 6 months to 2 years depending
on the scale of operation.
Last but not the least, boiler operating parameters are the key to energy savings
and unless you measure it, you don't get it.
Quiz
Once you finish studying the above course content, you need to take a quiz to obtain the PDH credits.
DISCLAIMER: The materials contained in the online course are not intended as a representation or warranty on the part of PDH Center or any other person/organization named herein. The materials are for general information only. They are not a substitute for competent professional advice. Application of this information to a specific project should be reviewed by a registered architect and/or professional engineer/surveyor. Anyone making use of the information set forth herein does so at their own risk and assumes any and all resulting liability arising therefrom.
