Reducing deaerator-related energy losses in steam boilers

Abstract

Improving energy efficiency helps to achieve a more reliable energy supply and a sustainable environment. In the current study, some observations were made in a textile factory to improve the energy efficiency of the industrial steam boiler. Deaerator is one of the main points of energy loss in the boiler. It is possible to reduce energy loss in the deaerator by using today's scientific and technological possibilities. The Failure Mode and Effects Analysis (FMEA) method was used in determining and ranking the factors causing energy loss in the deaerator. Some improvements were suggested based on the data of the FMEA study. The amount of energy loss in the deaerator was calculated by establishing mass and energy balances both in the current situation and after the improvements. As a result, when suggestions were applied, the energy loss in the deaerator, which was 373.6 kW before, could be reduced to 40.4 kW. Also, the net steam production capacity of the steam system will increase by approximately 9%. The payback period of the proposed investments was calculated as 2.8 months by performing the economic analysis. The study outcomes revealed that the FMEA technique, which is used as a risk analysis and failure prevention method within the scope of process improvement studies, can also be used to increase boiler energy efficiency.