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Improving Direct Efficiency of Boilers - Role of Automation

Safety and efficiency are always given a prime importance by both boiler manufacturers and steam users. Over the time, there has been a significant improvement in boiler performance as far as these two parameters are concerned. As the technology advances, there is always a scope to perform still better on safety and efficiency.

This article explains how intelligent PLC (Programmable Logic Controller) can help steam users ensure a more efficient and safer boiler operation.

In case of conventional manual fired solid fuel boilers, the gap between the indirect and direct efficiency is quite high. Generally, the typical efficiency guaranteed is somewhere around 73-77%. The efficiency which is actually obtained lies in the range of 50-55%. This huge gap between direct and indirect efficiency is on the account of many losses taking place which can be certainly reduced with the help of boiler automation. With the help of automation it is possible to provide alerts/inputs to boiler operator which assist him to operate the boiler efficiently. The system can also be used by utility managers for monitoring performance. This system, thus, when used properly can lead to substantial savings for users.

This article tries to understand the cause of gap between direct and indirect efficiency in case of manual fired solid fuel boilers and the role instrumentation can play.

Indirect and Direct efficiency- Why does the gap exist?

As we are aware, indirect efficiency is found out by calculating individual losses. Whereas direct efficiency is the ratio of heat energy generated by the boiler and energy supplied to the boiler in the form of fuel. This article explains the reasons behind gaps between direct and indirect efficiency.

How does manual operation lower the boiler efficiency?

In conventional manual fired boilers, boiler operations and adjustments like fuel fee