The document outlines various strategies for optimizing boiler systems and improving energy efficiency. Key recommendations include monitoring flue gas composition, installing heat recovery systems, conducting regular maintenance, and analyzing steam and gas flows to prevent waste. It emphasizes the importance of routine inspections and effective management of steam systems to reduce energy losses and operational costs.

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THERMODYNE ENGINEERING SYSTEMS

2.  Periodically monitor flue gas
composition and tune your boiler to
maintain excess air at optimum level
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3.  Recover heat from boiler blow down by
using heat exchanger to preheat boiler
makeup water
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4.  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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5.  Clear boiler waterside heat transfer
surfaces to prevent scaling in boiler
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6.  Insulate steam distribution and
condensate return lines to reduce
energy losses by 90%
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7.  Install removable insulation on valves
and fittings and also on components
requiring periodic inspection or repair
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8.  Upgrade boiler with new energy
efficient burner if repair costs become
excessive
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9.  Conduct burner maintenance at regular
intervals and install smaller burner on
boiler that is oversized relative to its
steam load
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10.  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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11.  Obtain the services of a water
treatment specialist to prevent system
scale and corrosion and to optimize
cycles of concentration
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12.  Install economizer as it recovers heat
from hot flue gases and preheats feed
water
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13.  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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14.  Develop and implement a boiler tuning
program to be completed a minimum of
once per operating year
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15.  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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16.  Improve efficiency of boiler through
maximizing the return of hot
condensate to the boiler
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17.  Use variable speed drives on large
boiler combustion air fans with
variable flows
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18.  Clean burners,nozzels,strainers and
inspect oil heaters for proper oil
temperature
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19.  Consider multiple or modular boiler
units instead of 1 or 2 large boilers
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20.  Make sure that boiler duty is at
optimum efficiency. For example, don’t
use two boilers at 30 percent output if
you can run one at 60 to 70 percent
output
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21.  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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22.  Make sure you are only generating
what you need. Measure the demand
and compare it with what the boiler is
generating. This will ensure you’re not
wasting steam heating up your factory
instead of your process
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23.  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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24.  • Remove soot deposits when flue gas
temperature rises 40°C 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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25.  • Recover heat from steam condensate.
For every 6°C rise in boiler feed water
temperature through condensate
return, there is 1% saving in fuel.
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26.  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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27.  • 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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28.  Install a dial type thermometer at the
base of the stack to monitor the
exhaust flue gas temperature
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29.  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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30.  Keep a check on the content of
combustion gases using flue gas
analyzer to adjust the air fuel ratio
accordingly
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31. Optimize the deaerator vent rate
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32. Recover thermal energy from
waste water streams
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33. 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@thermodyneboilers.com
Website: www.thermodynneboilers.com
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