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STEAM BOILER EFFICIENCY OPTIMIZATION

Industrial boilers in industry need to be operated efficiently to achieve higher steam generation efficiency to sustain production and competitiveness in the market economy. Generally, many operating boilers today are performing at efficiencies that are below the industry bench marks. Hence there is huge potential for energy efficiency improvements and cost savings that lead to higher profits. The bench mark efficiencies for water tube  combustion boilers with feed water economizers, air-preheating and 3% O2 in flue gas are 85.7% for natural gas -fired boilers and 89.6% (No.6 Fuel Oil-fired). Fire tube  boilers, running on residual fuel oil (RFO) at full load, on the other hand, achieves actual efficiencies of 80% maximum continuous rating (MCR); and 70% at low load efficiencies. 

The efficiencies in developing countries, such as Ghana, decline further due to inadequate boiler treatment and maintenance practices and lack of boiler efficiency measurement and monitoring systems. For instance, most boilers surveyed in Ghana and Nigeria had no steam measurement systems to monitor steam flow/production. The boiler efficiencies are therefore not based on steam-to-fuel ratio but on fuel consumption per unit production. Fuel consumption measurements are generally also based on inaccurate dip-stick measurements in fuel tanks instead of fuel meters with preheaters that give accurate and consistent flow rate metering. 

One of the key impact on boiler thermal efficiency industry is the continuous calcium and magnesium carbonate mineral scaling of boiler tube surfaces notwithstanding the practice of anti-scalant chemicals use in conventional scale control. The scaling reduces energy efficiency of steam generation and increases fuel consumption. It is estimated that 0.80 mm (80 micron) thickness of scale can potentially reduce boiler efficiency by 8-10%. As a result, steam boiler design increases heat transfer surface area by additional 20-25% over clean surface to compensate for mineral scale fouling. The impact of the scaling is significant decrease of boiler thermal efficiency to the range of 65-70%.

Industries therefore make every effort to achieve relatively higher benchmark efficiencies by equipping boilers with a set of efficiency improvement systems such as insulation of pipes and valves; condensate traps and return that increase feed water temperature; charging of anti-scalants chemical to slow down for scale build-up; use of feed water salt-softeners; and periodic shut-down chemical cleaning.

Energy Efficiency Improvement (EEI) and Carbon Emissions Reduction (CER) in Steam Boiler (SB)

The demonstrated steam optimization Tech-Transfer project assists industries to achieve sustained fuel and electrical energy savings, and optimization of process equipment operation and cost reduction, and reduced shutdown maintenance periods and cost in commercial and industrial steam boilers.  The specific reported benefits are:

We are the BEST steam boiler efficiency experts in AFRICA

The program provides state-of-the-art Add-on technology to achieve energy efficiency improvement additional to attainable efficiencies by all existing practices, quantifiable and demonstrated by measurement of steam flow and fuel consumption on continuous basis.

The add-on technology essentially achieves on-line continuous scale removal and control and thus minimizes the micro and macro level fouling of scale of heat exchange surfaces and enhances boiler energy efficiency and steam productivity. 

The increased and additional boiler efficiency attained and reported by the technology application in steam boiler operations are 5-15 % reduction in fuel consumption and equivalent greenhouse gas emissions reduction, 25-30% increased steam generation per ton of fuel,  and optimization and reliability of steam production for plant operations.

 
5-10%
Boiler thermal Efficiency Improvement

Boiler steam and process Optimization Benefits

Save with our innovative technology transfer projects 

Success stories

We are your choice for Energy Efficiency Improvement for sustainability, cost-savings, competitiveness and carbon emissions reduction

 
Carbon
emissions reduction equivalent of decreased fuel consumption
 
5-15%
reduced fuel consumption in packaged boilers (independent boiler maintenance practice)
Incremental thermal efficiency improvement WITH or WITH OUT conventional salt softening of make-up water for heat exchange equipment
Silica & rust being largely removed alongside mineral scale
 
>50%
savings in maintenance downtime for steam boilers, heat exchangers & boilers

Aberdeen Proven Grounds packaged boilers, Maryland package Boilers in the USA; leading to the subsequent adoption and installation on its water tube boilers, 2010

Unilever Plant, Ghana

Energy and Steam Efficiency Improvement in Packaged Boilers - July, 2010;

Effective descaling reduced shutdown maintenance time, increased steam efficiency and boiler water chemistry in packaged boilers of Forbes Marshal Plant, Pune. India – Nov, 2010; The project led to the adoption as add-on technology to its boiler production

SDG 12: responsible consumption and production in manufacturing value chains targeting, among others, reduced energy intensity in production, water conservation, and energy conservation

SDG 13: Climate actions including greenhouse gas emissions reduction

UN sustainable energy for All (SE4ALL) aimed at doubling energy efficiency in consumption and production systems have been embarked upon

Pheebe’s technology transfer for optimization

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Sustainable development benefits

The demonstrated steam optimization Tech-Transfer project assists industries to achieve sustained fuel and electrical energy savings, and optimization of process equipment operation and cost reduction, and reduced shutdown maintenance periods and cost in commercial and industrial steam boilers.  The specific reported benefits are:

Energy and Steam Efficiency Improvement in Packaged Boilers Coca-Cola, Nigeria Bottling Company (NBC) Plants, Nigeria -  November, 2006

Energy and Steam Efficiency Improvement in Packaged Boilers of Coca-Cola Bottling Company, Kumasi Plant, Ghana, 2005.

Pictures of Great Results achieved @ Coca Cola-Nigerian Bottling Company (NBC)

Assessment carried out by Independent Evaluation company (Edcomheltom Services Ltd.)