Energy Saving Tips For Steam Boiler - Thermodyne Boilers

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v THERMODYNE
THERMODYNE ENGINEERING SYSTEMS
ENERGY SAVING TIPS
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v THERMODYNE
ENERGY SAVING-DAY 1

• Periodically monitor flue gas composition and
  tune your boiler to maintain excess air at
  optimum level

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ENERGY SAVING-DAY 2

• Recover heat from boiler blow down by using heat
  exchanger to preheat boiler makeup water

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ENERGY SAVING-DAY 3

• Install an automatic blowdown control system as
  it optimizes blowdown rates by regulating water
  discharged in relation to dissolved solids
  present in water

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ENERGY SAVING-DAY 4

• Clear boiler waterside heat transfer surfaces to
  prevent scaling in boiler

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ENERGY SAVING-DAY 5

• Insulate steam distribution and condensate return
  lines to reduce energy losses by 90

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ENERGY SAVING-DAY 6

• Install removable insulation on valves and
  fittings and also on components requiring
  periodic inspection or repair

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ENERGY SAVING-DAY 7

• Upgrade boiler with new energy efficient burner
  if repair costs become excessive

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ENERGY SAVING-DAY 8

• Conduct burner maintenance at regular intervals
  and install smaller burner on boiler that is
  oversized relative to its steam load

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ENERGY SAVING DAY 9

• Develop and implement a routine inspection and
  maintenance program to check steam traps and
  steam lines for leaks. Repair leaks and replace
  faulty steam traps as soon as possible.

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ENERGY SAVING-DAY 10

• Obtain the services of a water treatment
  specialist to prevent system scale and corrosion
  and to optimize cycles of concentration

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ENERGY SAVING-DAY 11

• Install economizer as it recovers heat from hot
  flue gases and preheats feed water

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ENERGY SAVING-DAY 12

• Install air preheater as it recovers heat from
  hot flue gases and transfers this heat to
  incoming air for efficient combustion

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ENERGY SAVING-DAY 13

• Develop and implement a boiler tuning program to
  be completed a minimum of once per operating year

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ENERGY SAVING-DAY 14

• Consider installing turbulators on 2-3 pass
  boilers as turbulators can be a cost-effective
  way to reduce the stack temperature and increase
  the fuel to steam efficiency

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ENERGY SAVING-DAY 15

• Improve efficiency of boiler through maximizing
  the return of hot condensate to the boiler

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ENERGY SAVING DAY 16

• Use variable speed drives on large boiler
  combustion air fans with variable flows

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ENERGY SAVING-DAY 17

• Clean burners,nozzels,strainers and inspect oil
  heaters for proper oil temperature

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ENERGY SAVING-DAY 18

• Consider multiple or modular boiler units instead
  of 1 or 2 large boilers

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ENERGY SAVING-DAY 19

• Make sure that boiler duty is at optimum
  efficiency. For example, dont use two boilers at
  30 percent output if you can run one at 60 to 70
  percent output

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ENERGY SAVING-DAY 20

• If you measure steam or gas, measure the mass
  flow, not the volume flow. It takes ten times the
  energy to create 1 m3 of steam at 10 bar than at
  1 bar, yet the volume is the same

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ENERGY SAVING-DAY 21

• Make sure you are only generating what you need.
  Measure the demand and compare it with what the
  boiler is generating. This will ensure youre not
  wasting steam heating up your factory instead of
  your process

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ENERGY SAVING-DAY 22

• Steam metering throughout the entire distribution
  system is crucial for good energy management and
  to identify and implement energy saving measures

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ENERGY SAVING-DAY 23

• Remove soot deposits when flue gas temperature
  rises 40C above the normal. A coating of 3mm
  thick soot on the heat transfer surface can cause
  an increase in fuel consumption of as much as
  2.5.

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ENERGY SAVING-DAY 24

• Recover heat from steam condensate. For every
  6C rise in boiler feed water temperature through
  condensate return, there is 1 saving in fuel.

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ENERGY SAVING-DAY 25

• Boilers should be monitored for flue gas losses,
  radiation losses, incomplete combustion, blow
  down losses, excess air etc. Proper control can
  decrease the consumption upto 20.

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ENERGY SAVING-DAY 26

• Stop steam leakage. Steam leakage from a 3
  mm-diameter hole on a pipeline carrying steam at
  7kg/cm2 would waste 32 kl of fuel oil per year
  amounting to a loss of Rs. 3 lakh.

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ENERGY SAVING-DAY 27

• Install a dial type thermometer at the base of
  the stack to monitor the exhaust flue gas
  temperature

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ENERGY SAVING-DAY 28

• The refractory should be checked at least once in
  a month for their condition. Any damage in the
  refractory will lead to localized heating of the
  shell and damage to the same.

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ENERGY SAVING-DAY 29

• Keep a check on the content of combustion gases
  using flue gas analyzer to adjust the air fuel
  ratio accordingly

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ENERGY SAVING-DAY 30

• Optimize the deaerator vent rate

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ENERGY SAVING-DAY 31

• Recover thermal energy from waste water streams

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THANK YOU
v THERMODYNE

• THERMODYNE ENGINEERING SYSTEMS
• A-7 / 108 -110, SSGT Road Industrial Area,
• Ghaziabad, U.P. 201009
• Mobile No.  91-9891042944 / 91-9990212122
• 91-120-4110482 / 4562332
• Email sales_at_thermodyneboilers.com
• Website www.thermodynneboilers.com