Excess air provides safe operation above stoichiometric conditions. A burner is typically set up with 15% to 20% excess air in higher firing ranges. Higher excess air levels result in fuel being used to heat the air instead of transferring it to usable energy, increasing stack losses and significantly decreasing efficiency. Boilers with lower excess air throughout the operating range have higher efficiencies.
Emissions standards for boilers have become very stringent in many areas because of the new Clean Air regulations. The ability of the boiler to meet emissions regulations depends on the type of boiler and burner options. ZOZEN has options to meet 5ppm NOx regulations, as well as 1 ppm CO regulation at 30 ppm NOx out of the box. We can also custom-engineer Selective Catalytic Reduction (SCR) for more rigorous emissions controls.
Stack temperature is the temperature of the combustion gases (dry and water vapor) leaving the boiler. A well-designed boiler removes as much heat as possible from the combustion gases. Thus, lower stack temperature represents more effective heat transfer and lower heat loss up the stack. The stack temperature reflects the energy that did not transfer from the fuel to steam or hot water. Stack temperature is a visible indicator of boiler efficiency. Any time efficiency is guaranteed, predicted stack temperatures should be verified.
Stack loss is a measure of the amount of heat carried away by dry flue gases (unused heat) and the moisture loss (product of combustion), based on the fuel analysis of the specific fuel being used, moisture in the combustion air, etc.
Condensing boilers can achieve up to 98% thermal efficiency, compared to 70%-80% with conventional designs (based on the higher heating value of fuels). Typical models offer efficiencies over 90% when the return water temperature is at 110 ºF or less; the lower the return water temperature, the higher the efficiency gain.
This is because, under normal circumstances, the exhaust temperature of the boiler cannot completely condense the water in the flue gas, and the difference between the low calorific value and the high calorific value is mainly in the part of the latent heat of vaporization, so the low heat is used. The value is calculated to reflect the true efficiency of the boiler. However, there will be some special circumstances. For example, if the boiler is a condensing boiler, the calculation of the condensed water portion should be calculated using the high calorific value.
1. Your existing system is inefficient
Efficiency is key when it comes to plant heating. Utilizing efficient equipment can save your company a significant amount of money in the long run and it is better for the environment. If you know that your existing system is not as efficient as it could be and it is in need of repair, it may be worth looking into thermal oil system replacement.
2. Your existing system features helical coil technology
Helical coils are common in thermal oil heaters from most manufacturers. But there are many reasons why serpentine coils are the better way to go when it comes to thermal fluid heating. Repairs to helical coils can be so expensive and time consuming that in many cases you are better off investing in new equipment – and it is well worth it to consider a new thermal oil system that features serpentine coil technology instead.
Package boiler is a boiler that had been fabricated and available as a complete package. The entire pressure parts have been assembled in the workshop and ready to be sent to the field or site where power plant is located. On the field/site requires only connection and integration of course work in electrical connections, water pipes, steam pipes and fuel piping system to operate. Package boiler is one of classification of boiler based on erection. Design package boilers in general are the type of Fire Tube Boiler and have made up shell and tubes. This type has high heat transfer both radiation and convection.
Retrofitting a piece of equipment or an existing industrial heating system can be very challenging, but it can be especially frustrating if you haven't planned well ahead of time. You'll want to be sure that you've done your homework to ensure that retrofitting the piece of equipment you have in the way you have in mind is actually possible.
If it is possible, you'll want to work with the appropriate engineers to figure out exactly what it will entail, how much it will cost, what impact it will have on operations, etc.
