Boiler Operational Efficiency Best Practices from US DOE

Full technical report

In the report “Wise Rules for Industrial Energy Efficiency”, the EPA develops a comprehensive list of baic rules relating to boiler efficiency improvements.

• Boiler Rule 1. Effective boiler load management techniques, such as operating on high fire settings or installing smaller boilers, can save over 7% of a typical facility’s total energy use with an average simple payback of less than 2 years.

• Boiler Rule 2. Load management measures, including optimal matching of boiler size and boiler load, can save as much as 50% of a boiler’s fuel use.

• Boiler Rule 3. An upgraded boiler maintenance program including optimizing air-to-fuel ratio, burner maintenance, and tube cleaning, can save about 2% of a facility’s total energy use with an average simply payback of 5 months.

• Boiler Rule 4. A comprehensive tune-up with precision testing equipment to detect and correct excess air losses, smoking, unburned fuel losses, sooting, and high stack temperatures can result in boiler fuel savings of 2% to 20%.

• Boiler Rule 5. A 3% decrease in flue gas O2 typically produces boiler fuel savings of 2%.

• Boiler Rule 6. Every 40°F reduction in net stack temperature (outlet temperature minus inlet combustion air temperature is estimated to save 1% to 2% of a boiler’s fuel use.

• Boiler Rule 7. Removing a 1/32 inch deposit on boiler heat transfer surfaces can decrease a boiler’s fuel use by 2%; removal of a 1/8 inch deposit can decrease boiler fuel use by over 8%.

• Boiler Rule 8. For every 11°F that the entering feedwater temperature is increased, the boiler’s fuel use is reduced by 1%.

Fouling and deposition studies: studying other fields for improved understanding

  • Icing on aircrafts (water droplets)
  • Ash deposition in aero-engines (volcanic ash particles)
  • Deposition in gas turbines (soot and aerosols)
  • Respiratory tract studies (aerosols or sprays)
  • Spray coating (droplets of paint)
  • Diesel engines (diesel droplets)
  • Heat exchanger fouling in various industries such as crude oil, food, desalination, automotive or other processes.

Economic impact of high temperature corrosion in industrial boilers

Capital Costs.

• Replacement of equipment and buildings

• Excess capacity

• Redundant equipment

Control Costs.

• Maintenance and repair

• Corrosion control

Design Costs.

• Materials of construction

• Corrosion allowance

• Special processing

Associated Costs.

• Loss of product

• Technical support

• Insurance

• Parts and equipment inventory

Solid biomass barometer 2019 Eurobserv’er

Solid biomass energy consumption trend swings depend on public policies promoting its use, but they are also highly susceptible to weather conditions. In 2018, it was a mixed bag, with variations across its uses. The demand for heat declined in the European Union, due to a milder winter, while there was a rise in electricity production. All in all, the sector’s primary energy consumption was stable (0.3% lower than in 2017) and is still below the 100 Mtoe threshold (99.3 Mtoe).

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