Methods to increase energy efficiency of industrial boilers

Boilers are an essential part of many industrial facilities they serve to provide hot water
and steam for various applications, from sterilisation and cleaning to performing mechanical
work. As an indispensable tool, there are great benefits to be obtained from running these
boilers at optimum efficiency, providing the best performance, safety and energy efficiency
possible.
Boilers are also energy intensive components of industrial facilities. Steam generation
systems in the United States account for 34% of all energy used in production, and in the
United Kingdoms, up to one third of all energy consumption is used to heat water [1]. This
shows that increasing the energy efficiency of boiler systems can bring great improvements
to business operating cost and the environment.
What are boilers?
Most boilers have three parts: a burner that
converts fuel to heat, a heat exchanger that
transfers the heat to steam or hot water, and a
boiler vessel. A chimney stack draws off the
combustion by-products (flue gases), and the
steam and hot water flows through a
distribution system to its end uses. Natural gas
and oil are the most common fuel used in
boilers, though electric boilers are generally
found where combustion boiler pose fire risk
and where it is important to reduce emissions.
Figure 1: Boilers in an industrial application

Boilers face heat and energy losses through the following means:

Flue gas losses: These heat losses are due to the temperature of the flue gases and
are a function of excess air as well as the flue and combustion air temperature

Feedwater: Low feedwater quality leads to increased blowdown rate, and other
losses along the distribution system due to scale build-up

Radiation losses: This is the radiant heat loss from the boiler casing

Blowdown losses: Heated water is periodically discharged from boilers to control

concentration of suspended solids and prevent sludge formation

Ways to increase boiler energy efficiency

To minimise the heat lost by boilers, and to increase their energy efficiency, the above
sources of heat and energy losses can each be addressed by the following means:

Boiler combustion management: This aims to minimise excess air in combustion as

the more hot oxygen and nitrogen that escapes from the flue, the more energy is lost.
Oxygen concentration of the flue gas is analysed and can then be controlled and
adjusted.
Flue gas temperature is also a good indicator of boiler efficiency. By measuring flue
temperature and comparing its changes against steam load, ambient temperature,
and oxygen content, boiler efficiency can be monitored. Flue gas temperature should
be kept as low as possible to increase energy efficiency

Figure 2: Schematic of the operation of an industrial boiler

Pre-treatment of feedwater: Treatment of feedwater involves the removal of

impurities that can cause sludge build-up in the boiler and scale build-up along the
distribution system. Clarification and filtration of feedwater remove suspended
material, while demineralisation removes dissolved impurities

Boiler casing insulation: To minimise heat loss through radiant heat loss from the
boiler casing, proper insulation techniques and the maintenance of insulation layers
are required. Insulation must be ensured to be free from contamination by water or
other liquids which can affect its ability to retain heat

Blowdown heat recovery: Blowdown water contains significant energy that can be
recovered. Two main methods are used. Flash steam is created when blowdown
occurs and if the blowdown stream is directed to a flash steam vessel, the flash
steam can be recovered for low-pressure steam applications.
Blowdown water from either the blowdown stream or the liquid drain of the flash
steam vessel could also be used to pre-heat feedwater using a heat exchanger.

The energy efficiency of a boiler can also be increased with

the application of an economiser. This is a heat exchanger
that utilises the waste heat from the flue gas to pre-heat the
boiler feedwater, thus reducing the amount of input heat
required from the boiler to bring the temperature of feedwater
to required level.
Figure 3: Boiler economiser

The methods highlighted above will help to minimise the energy and heat loss as a result of
inherent restrictions in boiler design. To further increase efficiency of steam, hot water or
process heating systems, it depends, ultimately, on the system design. Facilities owners will
have to ensure boilers are sized according to process requirements, and keep in mind that
using a number of integrated smaller boilers to handle peak demand and possible expansion,
rather than one over-sized boiler. By adopting these methods and strategies, industrial
facilities owners will be able to gain from the improved energy efficiency of boilers and lower
operating costs.

For more information on increasing energy efficiency of industrial boilers, please visit:
http://www1.eere.energy.gov/manufacturing/tech_assistance/pdfs/steamhandbook.pdf
http://www.sustainability.vic.gov.au/resources/documents/Best_Practice_Guide_Heating.pdf

Contributed by H2PC Asia resource team of E2 writers. Please contact byap@h2pcasia.com

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[1]. Energy Efficiency Best Practice Guide: Steam, Hot Water and Process Heating Systems
http://www.sustainability.vic.gov.au/resources/documents/Best_Practice_Guide_Heating.pdf