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Boiler Basics 101: Economizers for Increased Efficiency

The price of fuel is constantly fluctuating and with it comes creative ways to be more economical. Finding methods to be more energy efficient is never a waste of time. In the boiler room, efficiency improvements can be found by many sources, however, a common option for energy savings includes the use of an economizer. What is an economizer? The economizer is a fabricated assembly of finned tubing that captures waste heat extracted from the boiler’s stack flue gases; the exhaust that leaves the boiler stack (or “flue”).

It’s all about the principle of Heat Transfer. While low temperature water, or feedwater, enters a boiler system, high temperature flue gas exits. An economizer captures heat from the flue gas that would typically go to waste, and utilizes it to preheat the feedwater. By doing this, an economizer is able to increase thermal efficiency by decreasing the energy required to heat the water to steam. This will typically result in a reduction of 1% in fuel cost per 10 degree rise in feedwater temperature. Overall, an economizer can be a major cost savings for boiler owners and will easily provide a quick return on investment.

The economizers’ simple technology and static parts provide longevity and low maintenance, and they are available in multiple designs and configurations. Conventional economizers are cylindrical or rectangular and come in a range of sizes for both firetube and watertube boilers. Rectangular designs are more commonly used for larger industrial watertube boilers, and can be configured for vertical or horizontal gas flows, finned or bare tube design, and other additional options if needed. A condensing economizer can improve waste heat recovery even further by cooling the flue gas below its dew point, reclaiming both sensible heat from the flue gas and latent heat by condensing the flue gas water vapor.

BOILER EFFICIENCY COMPARISON
  Combustion Efficiency at
4% Excess Oxygen
Stack Gas
Temperature
 Boiler  78% to 83% 350F to 355F
 Boiler with Standard Economizer  84% to 86%  250F to 300F
 Boiler with Condensing Economizer  92% to 95%  80F to 150F


When determining whether an economizer is ideal for your boiler equipment, the location of the economizer into stack is important. To ensure the most thermal recovery during the process, you need to make sure the economizer is installed as close to the furnace breach as possible. This will help avoid thermal loss and cooling.

At Nationwide Boiler, we offer our EconoStak economizer as an optional addition (or a standard addition in some cases) on our fleet of watertube rental boilers. The EconoStak consists of the economizer as well as all of the associated piping and structural supports required for very efficient and safe operation. In addition, we are a West Coast representative for E-Tech Heat Recovery Systems, a leading provider of economizers for new, replacement, and retrofit applications.

Contact Nationwide Boiler today to see if an economizer is the right option for you, and be sure to check out our previous Boiler Basics 101 blogs. We review various topics each month, so stay tuned for the next edition!

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Guest — aadax industry
very good and see our site http://aradax.ir
Monday, 09 December 2019 08:15
Guest — Emma
Nice blog. It will surely help beginners update their knowledge. The efforts you have put in to create the posts are quite interes... Read More
Tuesday, 10 March 2020 08:02
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Nationwide Boiler Inc. Exhibiting at Power-Gen 2010 - Booth 2578

Nationwide Boiler's sales team will be exhibiting at booth 2578 at the 22nd annual Power-Gen international trade show, December 14-16 at the Orange County Convention Center, Orlando, FL.

To receive a complimentary exhibit floor pass, please contact Nationwide Boiler at info@nationwideboiler.com.

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Nationwide Environmental Solutions - Read All About It!

Many people have asked about Nationwide Environmental Solutions (NES), Nationwide Boiler's strategic business unit, and now all the answers can be found on print.

NES' new brochure, which briefly summarizes NES' goals of providing total plant solutions by lowering NOx emissions and reducing energy consumption, showcases the CataStak family of products as well as an array of successful job photos. Whether your plant has boilers, gas-turbines, heaters, furnaces, OTSG's or anything else that is involved with combustion, NES has the solution.

Download our new brochure today, pass it along, and give us a call. Our sales team is here to help make your job easier by providing unmatched expertise, service and solutions. What do you have to lose?

 

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Commercial Industrial Boiler Efficiency Program - Offered by Enovity

EnovityDo you want to obtain no-cost, technical services and incentives for your boiler systems, while decreasing your energy costs? Enovity, a sustainability consulting firm, provides cash incentives for boiler efficiency improvements to commercial, industrial and agricultural customers in PG&E's service territory who pay the Public Good Charge or Public Purpose Surcharge and operate hot water or steam boilers.

Through Envoity's Commercial Industrial Boiler Efficiency Program, facilities were able to save over $2.8 million in annual energy costs and receive $2.9 million in cash incentives during the 2006-2008 Program cycle. As a result of Enovity's success, the Program will continue through the next funding period.

Enovity helps its customers identify boiler system energy efficiency opportunities at their facility, perform measurements and analysis to estimate energy savings, assist in the implementation of the energy efficiency upgrades (such as reviewing contractor proposals), verify the installation of measures and the final savings achieved, and provides a financial incentive to help buy down the cost of these projects. Enovotiy has also been instrumental in combining boiler energy efficiency with NOx upgrades in order to improved boiler capacity, improve operations and maintenance and reduce greenhouse gas emissions.

Examples of these measures include burner control upgrades (for 30 ppm NOx), burner combustion fan VFDs, and SCR installation and ULN burner replacement (such as replacing a high excess air, ULN burner with a low excess air 30 ppm NOx burner with a CataStak SCR system).

Benefits of participating in the Program include reduced energy consumption, reduced greenhouse gas emissions, reduced maintenance costs and improved system efficiency What do you have to lose?

For more information about Enovity's Commercial Industrial Boiler Efficiency Program, visit their website at: http://www.enovity.com/programs/cibep.html.

Also, read Nationwide Boiler's case study about how a major California food processor was able to receive cash incentives as well as energy and emissions reductions though the installation of a an E2Stak solution (CataStak SCR system and EconoStak economizer) and a condensing stack heat recovery system.

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Recent Comments
Guest — NBI Blogger
The costs associated for the maintenance and cleaning of an average industrial boiler depends on many things. It could range from... Read More
Thursday, 27 August 2009 12:35
Guest — Rodrigo A. Guajardo
Can you tell me how much is the cost in US dollars for the maintenance and cleaning of an average industrail boiler? Thank yu.... Read More
Wednesday, 26 August 2009 14:03
Guest — Ganesh
Great very helpful bog.One of the biggest problems with water-bath stand-by propane vaporizer systems is corrosion of the vaporize... Read More
Tuesday, 28 November 2017 06:35
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