How to improve boiler efficiency and extend boiler useful life

With energy prices increasing, you might be contemplating replacement as your best means to improve boiler efficiency. Still, even if replacement is not a consideration—and for most boilers it should not be—you can’t afford to stand by as energy costs burn up more and more of your plant’s budget.

Fortunately, owners of functioning industrial boilers have many avenues for getting more out of their units from the same or reduced fuel consumption. These are listed and described below.

At RoviSys, our job is to help our clients improve their industrial energy efficiency along with their overall production efficiency and capabilities. In fact, we don’t sell boilers or deaerators or automated blowdown systems. You’ll have to buy these elsewhere. Specifically, we:

Audit boiler controls and steam generation systems
Recommend ways to improve efficiency, capabilities and safety, including extending the life of existing boilers
Specify, design and implement boiler and steam system controls
Integrate your boiler and steam controls into your overall plant energy management and automation control and information systems

See steam as a system

Updating old or inflexible controls is generally considered the single most effective way to get more steam from less fuel. However, savings depend on how many hours you make steam, demand variations, energy costs and other factors. We recommend an audit of your boiler and steam system controls if you have uncertainty over your best options.

Beyond better controls, what's the key to uncovering and implementing savings in your steam and related operations? Understanding steam as a system—one that is part of a bigger manufacturing system. Integration across your plant or site is how you get the most steam from the fewest BTUs.

RoviSys steam generation systems engineers have been designing, implementing and supporting boiler controls and steam distribution systems for years. Applications include steel manufacturing, chemical plants, food processing facilities and refineries, to name a few. As part of a full-service and independent manufacturing automation solutions provider, we have developed the expertise and know-how to effectively maximize energy efficiency by bringing together the boilerhouse with clients' total manufacturing process.

What is real—and what is a “pipe dream”—when it comes to cost-effective improvements in your plant? We can help you answer those questions.

How to get more steam from your boilers using the same or less energy

For more on these topics, go the energy efficient boiler systems page.

Maintain and tune your boiler
Fix leaks and insulate piping
Measure combustion efficiency
Automate flue gas analysis to continuously
Recover flue heat with an economizer
Automate surface blowdown
Replace mechanical or linked burner controls with modern independent motor-driven fuel air-mixture controls
Polish your feedwater by removing contaminants and oxygen with filters and deaerators
Return steam condensate to your boiler feedwater
Replace fixed speed fans and motors with variable speed units
Reduce burner size on a boiler that consistently runs below optimum load
Buy efficient boilers properly sized for your needs
Sequence multiple boilers using a boiler management system that can communicate through your over plant control platform
Make only what you need: implement a load matching or leveling system to anticipate demand and increase or reduce supply accordingly

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Power/Energy Home Integration benefits Capabilities Experience Audits and analysis Campus Wide Energy management Industrial energy Savings overview Boiler controls Steam efficiency Chilled water Pollution controls Load balancing Energy monitoring Grants & credits Ohio programs State programs US Energy Programs Canadian programs Power Utilities Console replacement Balance of plant SO2 & NOX Control OSIsoft PI Dave Smrdel Manager Power and Energy 330.995.8209 The RoviSys Company 1455 Danner Drive Aurora OH 44202 330.562.8600 Southeast Office 2521 Schieffelin Rd. Apex NC 27502 919.387.1200	How to improve boiler efficiency and extend boiler useful life With energy prices increasing, you might be contemplating replacement as your best means to improve boiler efficiency. Still, even if replacement is not a consideration—and for most boilers it should not be—you can’t afford to stand by as energy costs burn up more and more of your plant’s budget. Fortunately, owners of functioning industrial boilers have many avenues for getting more out of their units from the same or reduced fuel consumption. These are listed and described below. At RoviSys, our job is to help our clients improve their industrial energy efficiency along with their overall production efficiency and capabilities. In fact, we don’t sell boilers or deaerators or automated blowdown systems. You’ll have to buy these elsewhere. Specifically, we: Audit boiler controls and steam generation systems Recommend ways to improve efficiency, capabilities and safety, including extending the life of existing boilers Specify, design and implement boiler and steam system controls Integrate your boiler and steam controls into your overall plant energy management and automation control and information systems See steam as a system Updating old or inflexible controls is generally considered the single most effective way to get more steam from less fuel. However, savings depend on how many hours you make steam, demand variations, energy costs and other factors. We recommend an audit of your boiler and steam system controls if you have uncertainty over your best options. Beyond better controls, what's the key to uncovering and implementing savings in your steam and related operations? Understanding steam as a system—one that is part of a bigger manufacturing system. Integration across your plant or site is how you get the most steam from the fewest BTUs. RoviSys steam generation systems engineers have been designing, implementing and supporting boiler controls and steam distribution systems for years. Applications include steel manufacturing, chemical plants, food processing facilities and refineries, to name a few. As part of a full-service and independent manufacturing automation solutions provider, we have developed the expertise and know-how to effectively maximize energy efficiency by bringing together the boilerhouse with clients' total manufacturing process. What is real—and what is a “pipe dream”—when it comes to cost-effective improvements in your plant? We can help you answer those questions. How to get more steam from your boilers using the same or less energy For more on these topics, go the energy efficient boiler systems page. Maintain and tune your boiler Fix leaks and insulate piping Measure combustion efficiency Automate flue gas analysis to continuously Recover flue heat with an economizer Automate surface blowdown Replace mechanical or linked burner controls with modern independent motor-driven fuel air-mixture controls Polish your feedwater by removing contaminants and oxygen with filters and deaerators Return steam condensate to your boiler feedwater Replace fixed speed fans and motors with variable speed units Reduce burner size on a boiler that consistently runs below optimum load Buy efficient boilers properly sized for your needs Sequence multiple boilers using a boiler management system that can communicate through your over plant control platform Make only what you need: implement a load matching or leveling system to anticipate demand and increase or reduce supply accordingly
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