Key benefits of boiler economisers
- Fuel efficiency: preheating feedwater decreases the fuel needed for steam production, leading to cost savings.
- Reduced emissions: lower fuel consumption translates to decreased greenhouse gas emissions.
- Extended equipment life: by reducing thermal shock, economisers contribute to the longevity of boiler components.
- Optimised performance: consistent feedwater temperatures ensure stable boiler operation and steam quality.
Types of economisers
Economisers are tailored to specific boiler systems and operational requirements:
- Non-condensing economisers: designed to prevent flue gas temperatures from dropping below the dew point, avoiding condensation and potential corrosion.
- Condensing economisers: capture latent heat by condensing flue gas moisture, offering higher efficiency gains but requiring corrosion-resistant materials.
- Finned tube economisers: utilise extended surfaces to maximise heat transfer from flue gases to feedwater.
Example of a boiler economiser in action
A manufacturing plant using a steam boiler system can integrate a condensing economiser to reclaim heat from exhaust gases. If the flue gas leaving the boiler is at 200°C, an economiser could recover sufficient heat to raise the incoming feedwater from 85°C to around 120°C. This reclaimed heat reduces fuel consumption by roughly 7%, significantly cutting fuel bills and carbon emissions while ensuring smoother boiler operation.
Boiler economiser: design considerations
Implementing an economiser necessitates careful planning:
- Material selection: components must withstand high temperatures and potential corrosive elements in flue gases.
- Flow configuration: counterflow arrangements enhance heat exchange efficiency.
- Maintenance access: design should facilitate easy cleaning to prevent soot accumulation and maintain performance.
- Control systems: integration with boiler controls ensures optimal operation and prevents issues like feedwater boiling within the economiser.
Conclusion
Integrating an economiser into a boiler system is a strategic move towards energy efficiency and sustainability. By effectively reclaiming waste heat, economisers not only reduce operational costs but also contribute to environmental conservation efforts. For facilities aiming to optimise their steam systems, investing in a well-designed economiser is a prudent choice.
Industrial boiler options
Whether you’re exploring steam boilers, industrial hot water boilers, electric steam boilers or other alternatives, Dunphy Combustion has the expertise and technology to support your needs.
