
Production costs are expensive due to the high cost of boiler fuel for the production process
Often the design of the boiler system from the outset is less than optimal. Things that often happen are:
- Using an open system. Do not take advantage of the heat from the rest of the steam by using an economizer.
- The steam distribution pipe is too small and too long and there are many elbows or reducers.
The boiler combustion system is not perfect because there is no balance between the supply of water, air, fuel and the combustion area.
Important points to note :
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Combustion in the burner is not optimal;
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Optimization and automation of boiler settings based on production/workload needs;
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Steam header size to suit the steam capacity and distribution pipe;
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Optimal energy isolation;
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Regular inspections to maintain boiler efficiency.

Simple Tips for Boiler Improvement
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Perform a technical audit of the boiler system. Technical audit points in general :
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Reviewing the As Built design with the current condition whether there have been many changes during the operating period.
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Calculating boiler system efficiency either by direct or indirect method.
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Conduct audits/check maintenance records or check the backlog of repairs that have not been carried out.
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Make a maintenance plan, repair and improvement results from the technical audit of the boiler system.
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- After conducting a technical audit involving a boiler specialist company to provide advice as a second opinion for improving the efficiency of the boiler system during the operating period.
- Carry out repair and improvement programs based on a priority scale with the available budget.
- Perform performance evaluation by comparing boiler performance before the improvement program with performance after improvement.
Efficiency Advantages
The main advantages that are most easily measured from boiler efficiency are :
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Reduced fuel costs to produce steam per tonne produced.
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The quality and quantity of the steam header produced is more measurable and better.
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The heat energy that is wasted from the system is decreasing.
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Reducing the impact of exhaust carbon emissions (more environmentally friendly).
Practical Everyday Tips to Maintain Boiler Efficiency
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Maintain balance/air supply ratio to burner
Air balance ratio is required to ensure complete combustion of the fire in the furnace. It is therefore important to know the percentage of air/steam for efficient combustion. Controlling excess air within the required range will result in reduced exhaust loss. In general, every 1% reduction in excess air supplied to the furnace results in approximately 0.6% increase in the overall efficiency of the boiler.
Practical Tips :-
Excess air must be reduced or avoided. Know the stoichiometric fuel-air ratio for your boiler as per boiler specifications.
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Keep checking the combustion gas content using the exhaust gas analyzer to adjust the fuel-air ratio accordingly.
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Conducting boiler system circuit inspection
A boiler is a high pressure vessel that produces high temperature steam for various purposes. The outer layer or structure is an important part which not only contains pressure but also keeps the flue gas temperature intact inside the boiler for efficient heat exchange.
Practical Tips :-
Boiler insulation should be checked for any damage or leaks. A simple way is to measure the temperature on the outside of the insulation with a temperature infrared gun. The higher the outside temperature, the more heat is wasted. Check the insulation for leaks or damage to the insulation layer. Ensure insulation is properly maintained to minimize heat loss and to maintain boiler efficiency.
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The combustion chamber/refractory must be inspected according to the boiler maintenance instructions to determine its condition. Any damage to the refractories will cause local heating of the shell. Check for black spots on the outer plate of the boiler. This is one indicator of a cracked and leaking boiler shell.
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Watch and control blowdown
Often blowdown is only performed when the water test results are high in chloride or when a high conductivity alarm occurs. This causes continuous uncontrolled blowdown. This makes the boiler efficiency decrease due to excessive heat dissipation as a result the boiler burners will burn longer to maintain steam pressure so that fuel combustion will increase.
Practical Tips :-
It is recommended to do a regular blowdown for a short time.
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Maintain chloride levels.
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Pay attention to the boiler workload (not too low or too high)
The best operating range for maximum boiler efficiency is 2/3 of the full load of the boiler. If the boiler is operated under 50% load, more air is required for fuel combustion thereby increasing heat loss. It is preferable to have a moderately high load rather than more at a low load. Errors in the selection of boiler capacity that are not in accordance with the operating load can be the main cause of non-optimal boiler loads.
Practical Tips :-
Avoid running the boiler at a load below 25% of the boiler capacity as efficiency is significantly reduced under this load.
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In general, boiler efficiency can be optimal if it is operated at a load range of 72–75% of full load.
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Pay attention to the soot left over from burning
Coal or oil fired boiler soot deposits are more susceptible to soot deposits on the tubes and internal surfaces of boilers than natural gas fuels. This can lead to a reduction in the heat transfer rate because the heat transfer contact area is covered with soot. The general calculation is that a 1% loss of efficiency occurs for every 22 oC increase in chimney temperature and 3 mm of soot can lead to a 2.5 percent increase in fuel consumption due to an increase in exhaust gas temperature.
Practical Tips :-
Therefore, regular cleaning of boiler tubes and economizers should be carried out. Record and observe the stack temperature for indications of soot deposits.