What are the specific energy-saving methods of boiler energy-saving renovation? What is the energy saving rate?

Industrial boiler energy-saving transformation technology can improve the thermal efficiency of the boiler, reaching 70%-80%, and saving 10%-15% of coal. The basic principle is to organically combine high-tech material technology, combustion technology and boiler comprehensive technology, and through a series of physical and chemical changes, burn coal to achieve enhanced combustion, full combustion and complete combustion, a new combustion method. This technology has been recognized by the country and users.

There is now a relatively advanced energy-saving technology: "Nano-micron high radiation coating technology". Nano-micron high radiation coating technology is to coat the surface of a heat transfer object with a layer of nano-micron particle size. , materials with high emissivity make the surface of an object have a stronger ability to absorb and radiate heat, improving the heat transfer efficiency of the object.

Nano-micron high-radiation coating technology changes the physical properties, morphology, chemical composition, organizational structure and stress state of the refractory material surface by coating a small amount of high-radiation material on the surface, and obtains excellent transmission. Thermal and mechanical properties, so it has good economic and technical properties.

Energy Saving Principles

There are three modes of heat transfer: convection, radiation, and conduction.

Generally speaking, when the temperature of the furnace body is above 900 degrees Celsius, the heat transfer is mainly radiation, and the radiation heat transfer is 15 times that of convection, accounting for more than 80%.

The emissivity of refractory materials at room temperature is generally 0.6 to 0.8. As the furnace temperature increases, it will drop significantly. It is only 0.4 to 0.5 at high temperatures, while high emissivity coatings can remain above 0.9. emissivity.

According to Kirchhoff's law, the absorptivity and emissivity of a material are equal. When the emissivity of an object's surface increases, its ability to absorb heat also increases accordingly.

Industrial Boiler Energy Saving Retrofit Technology - Energy Saving Efficiency Examples Taking the 24-hour coal saving of a 10-ton boiler as an example, the minimum designed coal consumption per ton of steam per hour is 150 kilograms.

The coal consumption per hour of a 10-ton furnace is: 150 kg × 10 = 1500 kg = 1.5 tons.

Coal consumption for 24 hours a day and night is: 1.5 tons × 24 = 36 tons.

Calculated based on a coal saving rate of 10%: 36 tons 3.6×300=1080 tons. Taking the northeastern regions of Liaoning, Jilin, and Heilongjiang as an example, the coal price is 600 yuan per ton, and the coal saving is 1080 tons × 600 yuan/ton = 648,000 yuan; a heating period of the heating furnace is calculated as 150 days: 50 × 3.6 tons = 540 tons, 540 tons × 600 yuan/ton = 324,000 yuan.

Industrial boiler energy-saving retrofit technology

- ① Install a fuel-fired boiler economizer; the molecular structure of hydrocarbons treated by the fuel-fired economizer changes, the number of small molecules increases, and the distance between molecules As the viscosity of the fuel increases, the viscosity of the fuel decreases. As a result, the degree of atomization and refinement of the fuel oil before combustion is greatly improved. It is sprayed into the combustion chamber and fully burned under low oxygen conditions. Therefore, the air blast volume of the combustion equipment can be reduced by 15% to 20% to avoid heat being taken away from the flue, and the flue temperature drops by 5°C to 10°C. After the fuel of the combustion equipment is processed by the economizer, due to the improved combustion efficiency, fuel can be saved by 4.87% to 6.10%. The flame is obviously bright and dazzling, the black smoke disappears, and the furnace is clear and transparent. Completely remove the coking phenomenon in the combustion oil nozzle and prevent re-coking. Eliminate the phenomenon of residue accumulation on the furnace wall due to insufficient combustion of fuel, achieving environmental protection and energy saving effects. The air pollution caused by exhaust gas emitted by combustion equipment is greatly reduced. Harmful components such as carbon monoxide (CO), nitrogen oxides (NOx), and hydrocarbons (HC) in the exhaust gas are greatly reduced, and the discharge of harmful exhaust gas is reduced by more than 50%. At the same time, the dust content in the exhaust gas can be reduced by 30%-40%. Installation location: Installed between the oil pump and the combustion chamber or nozzle. The ambient temperature should not exceed 360°C.

Industrial boiler energy-saving renovation technology

- ② Install condensing gas boiler energy saver;

Fume gas condenser Flue gas condenser Gas boiler exhaust smoke contains As high as 18% of water vapor contains a large amount of latent heat that has not been utilized. The exhaust gas temperature is high and the sensible heat loss is large. After burning natural gas, it still emits pollutants such as nitrogen oxides and a small amount of sulfur dioxide.

Reducing fuel consumption is the best way to reduce costs. The condensing gas boiler economizer can be installed directly in the existing boiler flue to recover the energy in the high-temperature flue gas and reduce fuel consumption. The economic benefits are very obvious. At the same time, the condensation and absorption of water vapor are Reducing pollutant emissions such as nitrogen oxides and sulfur dioxide in flue gas has important environmental protection significance.

Industrial boiler energy-saving renovation technology

- ③ Use condensing waste heat recovery boiler technology; In traditional boilers, the exhaust gas temperature is generally 160~250℃, and the water vapor in the flue gas is still In a superheated state, it is impossible to condense into liquid water and release the latent heat of vaporization. As we all know, boiler thermal efficiency is calculated based on the low heating value of the fuel, without considering the heat loss of the latent heat of vaporization in the high heating value of the fuel. Therefore, the thermal efficiency of traditional boilers can generally only reach 87% to 91%. As for the condensing waste heat recovery boiler, it reduces the exhaust gas temperature to 50-70°C, fully recovers the sensible heat in the flue gas and the latent heat of condensation of water vapor, and improves the thermal efficiency; the condensed water can also be recycled.

Industrial boiler energy-saving transformation technology

- ④ The tail of the boiler adopts heat pipe waste heat recovery technology; waste heat is energy that is not utilized in energy utilization equipment under certain economic and technical conditions, and it is also It’s redundant, wasted energy. It includes seven types: high-temperature waste gas waste heat, cooling medium waste heat, waste steam and waste water waste heat, high-temperature product and slag waste heat, chemical reaction waste heat, combustible waste gas waste liquid and waste material waste heat, and high-pressure fluid residual pressure. According to the survey, the total waste heat resources of various industries account for about 17% to 67% of their total fuel consumption, and the recyclable waste heat resources are about 60% of the total waste heat resources.

Superconducting heat pipes are the main heat transfer elements of heat pipe waste heat recovery devices and are essentially different from ordinary heat exchangers. The heat exchange efficiency of the heat pipe waste heat recovery device can reach more than 98%, which is unachievable by any ordinary heat exchanger. The heat pipe waste heat recovery device is small in size, only 1/3 of an ordinary heat exchanger. Its working principle is shown in the figure: the left side is the flue gas channel, the right side is the clean air (water or other media) channel, and there is a partition in the middle to separate them without interfering with each other. The high-temperature flue gas is discharged from the left channel. When the high-temperature flue gas is discharged, the high-temperature flue gas washes the heat pipe. When the flue gas temperature is >30°C, the heat pipe is activated and automatically conducts heat to the right. At this time, the left side of the heat pipe absorbs heat, and the high-temperature flue gas flows through the heat pipe. The temperature drops and the heat is absorbed by the heat pipe and conducted to the right. Under the action of the blower, clean air at room temperature (water or other media) flows in the opposite direction along the right channel to wash away the heat pipe. At this time, the right side of the heat pipe releases heat, heating the clean air (water or other media), and the temperature of the air increases after flowing through the heat pipe. A waste heat recovery device composed of several heat pipes is installed at the boiler smoke outlet. It absorbs the heat in the flue gas and conducts it to the other end at high speed, reducing the exhaust gas temperature to close to the dew point and reducing heat emission losses. The heated clean air can be used to dry materials or be replenished to the boiler for recycling. Improve the thermal efficiency of boilers and industrial kilns, reduce fuel consumption, and achieve energy conservation.

In the design and manufacture of industrial fuel, gas, and coal-fired boilers, in order to prevent corrosion and ash blocking of the heating surface at the rear of the boiler, the exhaust gas temperature in the standard state is generally not less than 180°C, and can reach up to 250°C. Flue gas emissions not only cause a lot of waste of heat energy, but also pollute the environment.

The heat pipe waste heat recovery device can recover flue gas heat. The recovered heat can be used to heat water as needed for boiler replenishment and domestic water, or heat air to be used as boiler combustion air or dry materials. Save fuel costs, reduce production costs, reduce exhaust emissions, save energy and protect the environment. The investment in renovation can be recovered within 3-10 months, and the economic benefits are significant.

Industrial boiler energy-saving renovation technology

- ⑤ Use anti-scaling and de-scaling technology; optimize the water vapor circulation system and reasonably control the boiler by using boiler descaling agents and electronic anti-scaling devices The discharge rate is reduced, thereby reducing scale and improving the thermal efficiency of the boiler.

Industrial boiler energy-saving transformation technology

- ⑥ Adopt fuel additive technology; add additives to the fuel to optimize the fuel, reduce soot and improve thermal efficiency;

< p>Industrial boiler energy-saving renovation technology

- ⑦ Use new fuel; Use new environmentally friendly fuel oil to achieve the purpose of reducing fuel costs.

Industrial boiler energy-saving transformation technology

- ⑧ Adopt oxygen-rich combustion technology; the oxygen content in the air is ≤21%. The combustion of industrial boilers is also performed under such air.

Practice shows that when the oxygen content of the gas burned by the boiler reaches more than 25%, the energy saving is as high as 20%; the boiler startup heating time is shortened by 1/2-2/3. Oxygen enrichment uses physical methods to collect oxygen in the air, so that the oxygen-enriched content in the collected gas is 25%-30%. Oxygen-enriched combustion is the latest energy-saving and environmentally friendly technology. In the past decade or so, with the continuous improvement of environmental protection requirements and the need to save energy, oxyfuel combustion as an emerging combustion technology has been booming in various countries around the world. Now some developed countries in the West require that all new industrial furnaces and industrial boilers must not If you use ordinary air to support combustion, you must use oxygen-enriched air to support combustion.

Industrial boiler energy-saving transformation technology

- ⑨ Use swirling combustion boiler technology; As we all know, traditional boilers have two major drawbacks. One is the emission of smoke and dust during combustion, which has become an important The source of pollution; secondly, the coal slag is not fully burned, resulting in extremely serious waste of energy. Compared with traditional industrial boilers, the new technology of pure smokeless and energy-saving swirling combustion boilers has absolute advantages. It saves 30% to 35% more coal than a hand-fired boiler and 25% more than a chain-type automated boiler. Because the pure smokeless re-energy saving technology uses PID frequency conversion and ABM power-saving systems, it saves 40% of electricity than traditional boilers. More than 90% of volatile components can be burned and utilized, while the burnout rate of volatile components of traditional boilers is only 78%. Around 22% of the smoke and dust is discharged into the atmosphere. Pure smokeless and energy-saving swirling combustion technology enables the ash and slag burnout rate to reach 97%, while the traditional boiler cinder burnout rate is only about 80%. It is for these reasons that Pure smokeless re-energy-saving combustion technology can increase the furnace temperature from the original 1200°C to about 1500°C, improving combustion efficiency, saving fuel, and meeting customer needs.

Industrial boiler energy-saving renovation technology

- ⑩ Use air source heat pump hot water unit replacement technology; replace the existing fuel (gas) hot water boiler with an air source heat pump hot water unit ;Can save energy consumption by 30% to 50%