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1. What is boiler operation?

Operating industrial boilers is a very important and complex job. Boiler operation is understood as all manipulation and control work according to the correct procedures to ensure that the industrial boiler operates continuously for a long time. In particular, indicators of flow, steam parameters, and hot water parameters must be accurate and effective.

At each business, for different purposes, boilers are used to create steam sources with different temperatures and pressures. The task of operating a boiler, in addition to satisfying consumption needs in terms of flow and economy, must also ensure safety during operation.

Therefore, the common point today is that manufacturing plants that use boilers are operated by separate management units. And the plant must comply with the boiler operating instructions provided by the boiler manufacturer. In particular, before, during and after the boiler operates, there must be a strict inspection process.

2. Steps of industrial boiler operating process

The operation of different boiler systems has different regulations and principles, both in terms of fuel supply system, control system, and ash and slag collection system. But the common point of boiler operation is that factories must comply with the boiler operating instructions provided by the boiler manufacturer and actual conditions.

Below is a basic industrial boiler operating procedure and some notes before putting the boiler into operation:

• Step 1: Inspection of the entire boiler system: Ensuring valves, water supply tanks, piping system tanks, measuring and safety equipment... have been assembled to meet technical requirements .

• Step 2: Carry out boiler operations: Start the furnace, fire mode, put fuel into the combustion chamber, supply steam, supply water, discharge dirt, maintain stable operation of the furnace...

• Step 3: Boiler shutdown (In case of necessity): Stop fuel combustion systems, close exhaust valves, exhaust fans, dust filters, monitor and check the entire system...

• Step 4: Maintain, clean, maintain the furnace... regularly for each type of boiler.

3. How to operate the boiler effectively and economically

To ensure the boiler operates safely and reliably with high economic targets, the factory must develop reasonable boiler operating procedures in all modes. Below, Thuan Hai introduces you to measures to help operate effectively and reduce energy loss and electricity consumption of boiler auxiliary equipment:

Control excess air coefficient and leaks at risky locations

• The position brings the ends into the smoke path.

• Inspection door or ash blow hole of the boiler, boiler joints.

• Position the wind shield at the ash and soot blowing hole.

• Location of burners, cracks in brick walls...

Check the combustion unit

• Check and calibrate the furnace combustion control system to ensure it is always in good working condition.
• Check the condition of the air flow control device: The air curtain and fan blades are always operating in the best conditions.
• Check the position of the airfoil to ensure the correct fuel/air ratio.
• Install equipment to analyze O2 in smoke.

Control exhaust temperature

• Clean boiler combustion surfaces regularly, at least once per shift. If the exhaust temperature still increases, the frequency of cleaning the furnace must be increased.
• Use an additional heat recovery device installed at the rear combustion surface (at the end of the smoke line) if the boiler in use has a flue gas temperature greater than 120ºC.
• Equipped with a heat saver
• Check the oxygen concentration before and after the air dryer once a month to control the tightness of the dryer.
• If using a cast iron water heater, the design must be carefully calculated to ensure that boiling does not occur in the heater. This is to avoid increasing pressure, causing the water heater to explode.

Control and recovery of condensate

• Saves additional water sources, greatly reducing the cost of treating water for the boiler.
• Minimize the concentration of impurities in water, reduce the amount of blowdown water, and reduce the energy consumed for blowdown.
• Utilize condensate to raise the supply water temperature without wasting additional energy as well as reduce the amount of steam supplied to the deaerator.
• Promotes increased thermal steam generation capacity without requiring additional energy supply.

Control blowdown flow

• Optimize discharge water flow, adjust discharge valve so that water quality remains at an acceptable level.
• Using an automatic discharge water control system will control the amount of discharge water. In practice, using an automatic blowdown system can save 20% of discharge flow.
• Minimize blowdown by recovering as much condensate as possible. Because condensate water will reduce the amount of impurities entering the furnace.
• Choose a water treatment system capable of minimizing scale formation in the furnace (usually applicable to new projects or newly renovated projects).

Water supply heating

• Using the condensate reuse method, place the furnace's water heater.
• Use other heat exchange methods.

Steam production using waste heat

• Install an additional steam generator that uses exhaust smoke at the output of the combustion chamber.
• Install a heater for Ethylene Glycol or oil taken to another place of use.
• Install equipment to heat oil supplied to the boiler.

Old boilers have flue gas temperatures ranging from 500 to 600ºC, so using an air dryer requires high manufacturing materials and is uneconomical. On the other hand, equipping these devices with air dryers will change the radiation characteristics of the combustion chamber, affecting the heat transfer process. Therefore, the above methods of utilizing heat can be considered.

Boiler thermal insulation

Check the insulation layer regularly and carry out timely maintenance and repairs to minimize losses because they can effectively radiate heat to the environment.
When insulating, attention should be paid to determining the optimal thickness of the insulation layer to achieve the desired insulation effect.

Replace boiler - Optimize performance and reduce costs

In some of the following cases, the factory needs to replace a new boiler:

• Old boilers in use lead to low efficiency and safety.
• The capacity is not suitable so starting up takes more time. Always running under load will result in lower performance and fuel consumption.
• Replace with Biomass boiler to burn agricultural waste by-products such as biomass fuel, agricultural and forestry waste such as wood chips, rice husks, coffee shells, cashew shells... contributing to environmental protection and Limit fossil energy.

In a highly competitive economic period, investing in a modern boiler system that can meet high efficiency is also a breakthrough step for every business. With the modern boiler systems that Thuan Hai is providing, installing and operating, it is contributing to helping businesses achieve high economic goals, minimizing costs. In addition, the professional operating system also optimizes human resources and streamlines the production area, thereby ensuring safety and helping customers feel secure about sustainable growth.

Customers who need advice on comprehensive solutions for investment, supply, installation and operation of boilers as required, please contact Thuan Hai for detailed and quick advice.