SAACKE energy efficiency

Optimizing efficiency
Identifying potential
Steam Flue gas loss
<
= 10%
Energy losses increase operating costs and place stress on the
Steam losses
Cooling down at every
environment. That is obvious. Fuel costs rise and today it is more burner start
<
= 0.6%
Radiation Loss <
= 0.35%
important than ever to use fossil fuels responsibly – not least of all < 0.25%
= Feed water
from an ecological point of view.
A modern firing plant therefore has to extract as much power as
possible from the available fuel – every quantum of fuel must be
exploited as thermal energy. A prerequisite for this is a high degree
of efficiency.
Blow-down loss
For this reason increase of efficiency plays a decisive role in the Blow-off loss

modernization of firing plant.

But how can one determine what energy losses are avoidable and,
above all: how can one minimize these losses? Heat losses of firing plants

How can optimal efficiency be achieved so as not to give away any

energy?
The two decisive factors for flue gas loss are
• the flue gas temperature and
The factors • the air surplus.

Mainly various types of heat losses negatively influence efficiency.
The following diagram illustrates this:
To be able to exploit the energy used through the fuel, optimizati-
on measures have to be taken particularly with regard to flue gas
losses.
The hotter the flue gas is, the more energy it contains. This means
hot flue gas gives off considerable unexploited energy to the
environment – and provides for a direct heat loss. Therefore, the
lower the flue gas temperature, the lower the heat loss – and the
better the efficiency of the firing system.

© SAACKE GmbH 2012 0-0750-0023-02

SAACKE GmbH | Head Office in Bremen: Südweststrasse 13 | 28237 Bremen | Germany | Tel.: +49 421 6495 0 | Fax: +49 421 6495 5224
International contact details: www.saacke.com | e-mail: info@saacke.com
 The second factor, the air surplus, is the difference between the SAACKE is intensively involved in efficiency increase of industrial
actually set and the theoretically required combustion air volume. A firing plants. We would be glad to offer you a calculation of the
low air surplus is necessary to ensure stable and low-emission potential for cost and emission reduction by means of the SAACKE
combustion.
2.4 With modern
Boiler Efficiency Rate firing plants it is between 8 % and Energy Efficiency Calculator – and then implement the appropriate
15 %. If the air surplus is too high, however, valuable unexploited measures for you.
. .
heat is lost.= (mfw - mbd) · (h – hfw)
ηb . · 100 in %
mF· LHV
Air ratio λL

Calculation of flue gas loss 18.0

1.00 1.05 1.10 1.15 1.20 1.25 1.30 1.35 1.40 1.45 1.50

17.0
2.5 Determination of the Boiler Efficiency Rate 16.0
380°C

The from theloss

flue gas Flue Gas
can beMeasurements*
estimated with the help of the Siegert 15.0
14.0
360°C

340°C

Flue gas loss in %

formula.
320°C
13.0 300°C

ηb = 100% – Xf% – 2%(max) in % 12.0 280°C

260°C
11.0
240°C

10.0 220°C

9.0 200°C

180°C
8.0

( A
)( )
160°C
7.0

Xf = + B · ϑf – ϑa in % 6.0
140°C

21 - O2,dry
120°C
5.0
100°C
4.0
3.0
2.0
Xf = flue gas loss 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5

ϑf = flue gas temperature in °C Measured O2 in dry flue gas in % by vol.

ϑa = combustion air temperature in °C
O2,dry = O2 value measured in the dry flue gas in vol. % Flue gas loss according to Siegert formula

A and B: constants

110
EL fuel oil HFO Nat. gas Liquid gas Town gas 108

A 0.68 0.69 0.66 0.63 0.63 106

Natural gas combustion
B 0.007 0.007 0.009 0.008 0.011
Firing system efficiency in %

104
Oxygen content = 1%
102 Oxygen content = 3%
* Calculation basis: 1st German Immission Control Act (1. BImSchV) Oxygen content = 5%
hF in %

100

98

96

The above-mentioned parameters are inputted in this formula 94

directly or indirectly. 92

90

The following figure shows a selection of results of the Siegert 88

25 50 75 100 125 150 175 200 225
formula. 19 Waste gas temperature in °C

Improvement of firing plant efficiency by means of condensing appliance

In addition to flue gas losses, energy losses of fans or radiation
technology
losses of the boiler also have a significant impact. All loss factors
Rules_2011.inddhere can be minimized, as a whole or individually.
inhalt19 14.12.11 11:10

A brief excerpt from our portfolio

• Minimization of auxiliary energy, such as by using variable • Service or process water heating
speed motors (condensing appliance technology)
• Highly efficient secondary heating surfaces (air pre-heater, • Optimization of mode of operation and control parameters
economizer) • Minimization of startup losses by means of burner start with
• Minimization of air surplus by means of prepurging sequence
CO- / O2-control

For further information, please visit: www.saacke.com

© SAACKE GmbH 2012 0-0750-0023-02

SAACKE GmbH | Head Office in Bremen: Südweststrasse 13 | 28237 Bremen | Germany | Tel.: +49 421 6495 0 | Fax: +49 421 6495 5224
International contact details: www.saacke.com | e-mail: info@saacke.com