Boilers are widely used for space heating, water heating and a variety of other processes. While they're critical for building comfort and your operations, boilers use (and waste) a lot of energy. The following strategies can help improve the efficiency of your boiler system, reducing the pressure on your operating budget.
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1. New burners
New burners are more efficient and improve fuel combustion while lowering emissions of nitrogen oxide. They support linkageless controls and higher turndown ratios, which reduces short cycling.
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2. Temperature reset controls
Temperature reset controls match the supply of hot water with the demand for heat, instead of supplying hot water at a higher temperature than needed. The system water temperature is reset based on the outdoor temperature. If the outdoor temperature increases, the boiler water temperature is decreased.
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3. Boiler economizers
Boiler economizers capture waste heat in the exhaust flue gases to preheat the boiler feedwater. A boiler equipped with an economizer, operating at a stack temperature of 500°F and 80 percent excess air, would realize a 7 percent fuel savings. The stack temperature must be kept at a minimum of 250°F to avoid condensation of the water vapor in the flue gases.
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4. Baffle inserts
Baffle inserts induce combustion gases to flow in a turbulent spiral pattern inside the tubes and are typically used in multi-pass firetube boilers. This turbulence increases the efficiency of heat transfer, which reduces fuel consumption.
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5. Linkageless controls
Linkageless controls replace mechanical linkages--which use levers, jackshafts, cams, chains and gears--with direct digital control. Linkageless control systems include combustion sensing equipment, precise modulators for fuel and air and an exhaust gas analysis feedback system. The benefits include more precise control of firing rates, higher turndown ratios, easier implementation of multi-burner and duel-fuel capabilities and fuel savings.
If your boiler system is older or in need of major repair, consider upgrading to a new, high-efficiency unit that's sized correctly to fit your needs. A system upgrade can reduce your energy costs by 10 to 30 percent. Check with your local utility about rebates or incentives for boiler upgrades or replacements.
For further information on combustion efficiency, see these tips from the U.S. Department of Energy.
Learn more about our energy efficient heating equipment incentives or call 855-236-7052 to speak with an energy specialist.