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Smart scale energy solutions for steam systems

Monitoring the efficiency of steam boilers pays off

A typical steam boiler often consumes many times the initial capital expense in fuel usage annually. The investment cost for a boiler can easily be five times lower than the yearly fuel consumption. Consequently, a difference of just a few percentage points in boiler efficiency between units will result in substantial fuel savings. Our smart scale energy solutions for steam systems help you to monitor your boiler's efficiency.

Boiler efficiency

Key factor to benefit of continuous cost reduction is monitoring the fuel usage or boiler efficiency. It accounts for the effectiveness of the heat exchanger as well as for the radiation, convection and blow down losses. This helps to:

  • Gain transparency of the fuel and steam consumption

  • Identify, quantify and allocate losses in the system

  • Benchmark boiler and consumers and optimize their use

  • Minimize maintenance cost and downtime

  • Verify investments

  • Evaluate most efficient operation load of boiler and production

Steam balance and leakage

A lot of energy is lost in steam systems due to improper insulation or leakage found at valve stems, unions, pressure regulators, pipe joints and defect steam traps. Mass balancing by measurement at different points in the steam system helps to:

  • Detect leakages in time

  • Define ideal maintenance intervals and justify expenses

  • Find weak points in insulation

  • Quantify and reduce condensate losses and thus save valuable energy, reduce make up water and chemical

Specific energy consumption

The allocation of energy usage to specific areas and processes is one of the key factors for energy management systems (e.g. ISO 50001) and precondition for transparent bookkeeping. The exact measurement of air consumption per unit of product is also helpful to optimize production processes. Furthermore the data are suitable for a carbon footprint evaluation.

Monitoring constantly

Constant monitoring of a steam boiler and the steam system is the key to improving system performance and detecting changes at a early stage.
Define the right KPIs which help you to evaluate:

  • Steam boiler efficiency

  • Steam balancing and leakage

  • Specific energy consumption

This is the precondition for energy management and cost reduction.

  • Monitoring the efficiency of steam boilers pays off ©Byworth Boilers

    Monitoring the efficiency of steam boilers pays off

  • Smart scale energy solutions for steam boilers for substantial fuel savings ©Endress+Hauser

    Smart scale energy solutions for steam boilers for substantial fuel savings

  • Steam leakage in a production process ©Endress+Hauser

    Steam leakage in a production process.

  • Continuous cost reduction by monitoring the fuel usage or boiler efficiency ©Endress+Hauser

    Continuous cost reduction by monitoring the fuel usage or boiler efficiency

  • Constant monitoring of a steam boilerand the steam system is key to improving system performance ©Endress+Hauser
  • Steam leakage ©Endress+Hauser

    Steam leakage

Contact

Endress+Hauser (India) Pvt. Ltd.
Pirojshanagar , Godrej One, 7B, 7th Floor, Vikhroli - (East) Maharashtra Mumbai 400079 , India
Tel.: +91 22 30236100
Send email

References

  • ArcelorMittal Zenica in Bosnia and Herzegovina produces hot rolled products (rebars, wire rods, mesh, lattice girders, classic construction armatures) mainly for the Balkan, EU and North African markets.

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