Steam generation systems can generally be classified into two principal types: fired boiler systems and waste heat systems. The primary purpose of an effective steam generation system is to produce steam under the conditions - flow rates and pressures- required for the system end-use requirements. It is important to generate the steam at the highest possible generator efficiency. It is equally important that high-quality (dry) steam be produced; transmission of wet steam to the distribution system can lead to water hammer and also to inefficiencies in the end use of the steam produced.
Key components include the boiler itself, boiler system components including controls, valves piping and meters, water treatment equipment, economizers, and deaerators.
Key Inputs and Outputs
Key inputs include boiler feedwater, condensate returned, water treatment chemicals and air/oxygen input. Key outputs include steam mass flowrate, steam pressure, steam quality, combustion gas conditions.
Opportunities for Improvements
Determine the efficiency of your steam generation system (based on steam output/fuel input).
Determine how much steam you use, and how much it costs to generate this steam. Steam generation needs to be measured with accurate, well maintained and calibrated flow measurement devices and reconciled by a rigorous steam balance. The steam balance should be done on a regular basis to confirm that the flow measurements are good.
Optimize excess air in your boiler to increase steam generation efficiency. An often stated rule of thumb is that boiler efficiency can be increased by 1% for each 15% reduction in excess air or 40° F reduction in stack gas temperature. Good measurements of fuel flow and air flows are required to do this as well as good stack gas analysis.
Maintain clean fire-side and water-side boiler heat transfer surfaces. A good deposit control program is necessary to do this.
Optimize boiler blowdown to reduce Total Dissolved Solids (TDS) in the boiler system. Work closely with your boiler feed water additives vendor to do this.
Optimize your boiler control system to optimize steam generation efficiency. Before you do this, make sure that the logic diagrams actually reflect what is wired into the system and that all the components of this system make sense and work.
Ensure that an effective water treatment system is in place. Work closely with your boiler feed water additives vendor to do this.
Finding More Information:
Under Technical Resources - See Technical References and Standards, Steam Tips, Technical Tools