Optimising Steam Boilers Efficiency in Three Ways

In process industries for edibles such as fruits and vegetables that might include facilities where dehydration, drying and freezing of edible products take place, steam is the main driving force. Steam, in these plants work as fuel whereas steam boiler efficiency can return sufficient savings in terms of money, energy, time and resource. Boiler systems generate adaptable steam which is used for many different purposes such as heat sterilisation, peeling, evaporation, pasteurisation, container and equipment cleaning, indirect drying and more.

Dramatic energy savings can be achieved with just the precise steam boiler efficiency and accurate use of pressure transmitters; critical for measurement. In order to make the steam systems work more efficiently, there’re numerous tweaks, upgrades and retrofits performed whereas follow-up procedures are just shortlisted improvements that substantially impacts the outcome.

Steam Boiler Efficiency

Successful improvement in the process boiler control isn’t all too complex or deep especially for industry-sized, large boilers with potential operating cost for capital investment linked with better efficiency. Vent/chimney or flue gas gauges optimum temperature of the flame, tracks carbon monoxide (CO), smoke and oxygen. When oxygen monitoring system works in combination with intake airflow, even the smallest leaks can be detected thereby achieving greater efficiencies and maximum output.

With more advanced and sophisticated controls, plant can be efficient and optimise fuel/air mixture for high flame temperature, becoming highly energy efficient and significantly lowers the emission of air pollutant. The calculation would allow significant reduction in consumption of natural gas almost anywhere between five and ten-percent with almost one-year-plus payback period. Other measures worth consideration are proper sizing of the boiler systems, improved boiler insulation and constant, consistent maintenance of the boiler.

Measurement of Steam Boiler Efficiency

Usually, hot water and steam distribution systems are far too complex, advanced and vast whereas contributors to energy loss in all such processing plants and facilities can be many. The key focus of efficiency agenda is reducing heat loss throughout the system and salvage useful heat from the system wherever necessary and feasible. Better insulation, thorough maintenance and close monitoring make a huge difference in overall system performance and efficiency.

In addition, regular checking and maintenance of the steam traps for commencement of proper operations can save significant energy for least monetary spent. Nearly 15-to-20 percent steam trap malfunction in a steam distribution system is common if you’re proceeding without a robust steam trap maintenance programme and guide reports. On incorporating a regular system of steam trap checks into the operations, more or less 10-percent energy savings can be achieved as projected.

Process Integration

Facilities with extreme heating and cooling demands such as food processing industries, process integration techniques can significantly reduce energy consumption as a whole. Take for instance, rejected heat within a facility during the cooling process can be recouped and reused in numerous process heating applications. Savings can be substantial whereas payback period is more or less two-to-three years.

Pressure transmitters here also play an important role for accurate measurement of the liquid and gas pressure without which nothing can be achieved or chances of error are greater.

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