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FACWORLD EZINE
The Facilities, Mechanical, Electrical Resource Center

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August 1, 2005
Editor: Thomas Yoon

contact: http://www.free-marine.com/emailform.htm
Publisher: Facworld Ezine


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Publisher's Note
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Publisher's Note
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Hi there,


With the rising cost of fuel prices, industries that use steam
boilers for heating or power generation are hard pressed to
operate at peak efficiencies.

While steam consumption, leakages, and other heat transmission
losses can contribute to the overall energy bill, this article
focuses on the heart of the steam generator - the boiler.

Controlling the boiler is of utmost importance in any steam
generation energy saving program. Below are some ways to
improve boiler efficiencies:

1. Reducing excess air
2. Installing economizer
3. Reducing scale and deposits
4. Reducing blow down
5. Recovering waste heat from blow down
6. Stopping dynamic operation
7. Reducing boiler pressure
8. Operating at peak efficiency
9. Preheating combustion air
10.Switching from steam to air atomization
11.Switching to lower cost fuel


Reducing Excess Air

Adjusting the fuel-air ratio for combustion can be quite tricky.
If the fuel is too much as compared to the air, incomplete
combustion occurs. This will give rise to carbon soot deposits
inside the combustion chamber or even over the boiler tubes.

The consequences of having soot deposits over the heat transfer
surfaces and the potential of having explosive flue gases inside
the boiler are much worst than losing a slight amount of energy
through the exhaust stack. Therefore, many boiler operators
choose to adjust their burners to be slightly on excess air.


Installing Economizer

This is only appropriate if there are insufficient heat transfer
surfaces in the boiler. To avoid corrosion, careful design is
needed to ensure that the exhaust flue gas temperature does not
drop below the dew point.


Reducing Scale and Deposits

For any boiler operation, this is a must. The safety of the
boiler is at stake. Any scale or deposits will lead to reduced
heat transfer that will eventually lead to overheating, reduction
of mechanical strength of the steel and finally to bursting.

This should already be in the normal daily procedure of boiler
operation.


Reducing Blow down

As steam is generated from the evaporation of water, the remaining
water in the boiler becomes more and more concentrated. This must
be drained away during blow down.

The challenge is to control the draining to the minimum.


Recovering Waste Heat from Blow down

Since it is necessary to blow down to control the total dissolved
solids in the boiler water, methods can be adopted to recover back
some of the heat from the drained hot water.


Stopping Dynamic Operation

Whenever a boiler starts or stops, a few minutes are spent running
the forced draft fan for purging the combustion chamber of unburnt
gases. This is a necessary step for the safe operation of a boiler.

During this time the heat from the boiler water in the shell or
tubes will be lost to the purging air. Maintaining a steady firing
condition in the boilers will prevent the start-stop operation.


Reducing Boiler Pressure

By reducing the boiler pressure, some of the heat losses through
leakages or transmission may be reduced slightly. However there can
be problems with the boiler with reduced pressure. The boiler
circulation may be upset and the steam lines may have insufficient
capacity and flow to transport the low pressure steam.


Operating at Peak Efficiency

When operating two or more boilers, improved efficiency can sometimes
be obtained by unequal sharing of the load so that the combined load
operates at peak efficiency.


Preheating Combustion Air

Any heat loss from the skin of the boiler to the boiler room can be
utilized back for combustion. By preheating the intake air the
combustion in the furnace becomes more efficient.


Switching from Steam to Air Atomization

For burners with steam atomization, switching to air atomization will
naturally result in less steam consumption overall and better boiler
efficiencies. This is only applicable for heavy fuel oil burners.


Switching to Lower Cost Fuel

The reason for this is that in the combustion process, hydrogen
combines with oxygen to form water. The latent heat of vaporization is
lost when water vapor leaves the boiler stack.

Fuels like natural gas with higher hydrogen to carbon ratio will lose
this heat more than those with lower hydrogen-carbon ratio like fuel
oil.

However one must also recognize that there will be increased
maintenance, operating costs and greater need for more excess air in
order to achieve complete combustion for fuel oil. In addition, soot
deposits and incomplete combustion might also affect the overall costs.


Some of the ways mentioned above may not be feasible at all for your
plant. Each of them may result in only a few percentage points of
boiler efficiency improvement. However, if carried out carefully and
with the proper tools and instruments, they do add up to huge savings.
Find the tools at http://www.free-marine.com/linkeastwood.htm and
http://www.free-marine.com/linknortherntool.htm


Until next time...

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Thomas Yoon
Editor, Facworld Ezine
More information can be obtained at
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Article
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Marketing through Television

Pretty much everyone watches TV so using the television as a
way to market your company or product is a very good idea.
Using the television as a marketing approach is very good
for many reasons. One great reason is that you can connect
with your customers or personal customers in a very direct
and sometimes emotional way. You can make them feel you and
see you and this makes them more likely to use your product
or service. It also works because they may see the
commercials and advertisements many times a day ~ depending
on how much TV they watch. This makes it almost like the
power of suggestion and they want your product.

Instead of relying purely on text or on sound, you can use
television adverts to illustrate what you are saying with
movements. Showing someone actually using your product is
a great way to build confidence in your idea. Many
companies also use items such as cute animals and children
to appeal to a wide range of people.

Inexpensive TV Ads

Businesses are often put off from using television
marketing because of the costs involved. Cutting corners
can be dangerous as a badly made advert will imply that
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Having said this, you need not spend a fortune! Get hold of
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