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In many industrial factories today, boilers and heat networks are one of the indispensable systems. This system consumes a significant amount of fuels such as: gas, coal, oil, biomass fuel...this inevitably wastes energy, so is there any solution to save energy in the boiler system To solve this problem?
Boiler systems and other heat networks are complex in factories with systems of valves, pipelines, and equipment, with the main task being to produce and distribute steam to serve the needs of drying and heating. heat, pasteurization,... including electricity generation in cogeneration plants. To provide the best solution for your boiler, you need to clearly understand the operating process of this system.
OPERATION PROCESS.
The main task of the boiler system is to distribute steam through pipes, valves and auxiliary equipment to consumption locations and reduce the pressure of steam to the required pressure at a separate address. . The steam stream, after being used and exchanging heat, will be converted into condensate and returned to the boiler to turn into steam.
Accordingly, the solution here is to optimize the combustion process inside the furnace, optimize the heat exchange process inside the furnace and minimize damage to the outside environment, taking advantage of the excess heat source of exhaust smoke.
According to studies, losses due to incomplete combustion in coal-fired boilers are about 20-30% of the energy consumed in the furnace. Accordingly, the carbon content in slag ranges from 15-35% on average. Therefore, optimizing the combustion process will help release more energy and save fuel.
The optimization process includes: Ensure reasonable moisture level of coal: coal dust is often watered to retain heat and improve the burning process. However, this method will reduce the calorific value of the coal, and the amount of unburned coal will increase due to the loss of heat to evaporation. Reduce excess air coefficient to the lowest: excess air coefficient is the amount of air supplied for the combustion process more than the amount of air theoretically needed for that combustion activity. When this coefficient is high, it will reduce the combustion chamber heat, making combustion more difficult and increasing heat loss due to exhaust smoke. The excess air coefficient can be checked by measuring the concentration of Oxygen and Carbon in the exhaust smoke. Solution: renovate the combustion grate, renovate the coal page method and supply air to each area in the furnace so that the contact between air and fuel is in the best state. Make sure the combustion chamber must be tight: cold air entering the combustion chamber will reduce the temperature in the combustion chamber, affecting the combustion process in the furnace, so maintain the pressure inside the combustion chamber at 8-10mm H2O. Solution: Adjust the flow of the fan and exhaust fan, install an inverter for the fan and exhaust fan to both save electricity for the fan and easily control the fan.
The heat exchange process in the boiler is sometimes not paid attention to, so how to save energy for the boiler needs to be carried out step by step. Treating water entering the furnace: removes scale components in the water before putting it into the furnace, which can be removed by a water treatment system using cations for the best heat exchange efficiency of the furnace. Maintain a reasonable furnace discharge schedule: water enters the furnace and evaporates into steam, and the amount of dissolved matter stuck in the furnace increases. If left for a long time, it will form scale on the metal walls. The furnace should be drained periodically and continuously, and promptly added new water so that the concentration of dissolved substances in the furnace water does not exceed the allowed level. However, when the furnace is discharged, it also loses some heat to heat the water, so there should be a reasonable and optimal discharge schedule. Utilizing excess heat from exhaust smoke: In many boilers, the amount of smoke discharged from the furnace has high temperatures because the heat generated from the combustion of fuel has not been fully utilized. You can take advantage of the heat from this waste smoke to warm water before putting it in the oven, dry the air supplied in the oven, dry FO oil, etc. Be careful not to let the smoke temperature drop below 120 degrees Celsius because of the smoke temperature. Low levels will easily corrode smoke pipes, causing pollution to the surrounding environment in cold and humid weather.
To reach the required location, it is inevitable that there will be heat loss through the pipe wall to the outside environment, steam loss through leaky joints, or holes in the pipe due to abrasion or corrosion. . Solution: Make sure to insulate, insulate both valves and connectors with special covering structures. The leaking point needs to be sealed as soon as possible.
OPTIMIZE STEAM EQUIPMENT PERFORMANCE (TERMINAL DEVICES).
The performance of steam equipment also equally affects the overall performance of the boiler and heat network. To improve this performance, proper cleaning is required to prevent scale build-up, which reduces performance. Choosing the type of steam trap (Steam trap - separating condensate from steam) also plays an important role in reducing steam loss and enhancing the performance of steam-using equipment.
INSTALLATION AND IMPROVEMENT OF CONDENSATE WATER RECOVERY SYSTEM.
Many factories do not have condensate recovery systems, wasting energy, clean water, and water treatment chemicals. If your business does not have a condensate water treatment system, you should install it because it saves a lot of energy for the boiler system. If you already have a condensate recovery system: the reclaimed water pipes should be insulated, and the reclaimed water tank should also be insulated. The amount of water recovered will be fed into the furnace along with an additional amount of water. When the water temperature entering the furnace increases by 6 degrees Celsius, we can increase the efficiency of the boiler system and heat network by 1%, thereby significantly reducing fuel consumption. Hopefully, some of the energy-saving solutions in the boiler system shared above will help you improve performance, save on fuel consumption costs, and reduce heat loss during operation. ….. If you have any questions, please contact us directly to receive the most complete advice.