Improving boiler efficiency by 6.3% for a textile manufacturer using Forbes Marshall Digital

Boiler efficiency was 79% while their target was 84%

S:F ratio was 6.2 against a target of 6.5 Kg/Kg

Blowdown total dissolved solids (TDS) was 8518 ppm, above the limit hence, posing a risk of scaling/corrosion.

The ON/OFF cycle was at 1.3cycles/hr causing efficiency loss.

EverSense platform provided for data on boiler efficiency, steam to fuel ratio, steam flow and pressure, oxygen %, stack temperature, drum TDS, feedwater temperature, furnace pressure and ON/OFF cycles.

Uptime monitoring of key equipment and parameters helped identify the fuel’s high moisture content and small particle size.

Digital monitoring enabled faster corrections of the following issues:

• Zero calibration and cleaning of draft transmitters carried out.
• O₂ and TDS sensors cleaned, refitted, and optimised.
• FD (forced draft) fan parameters fine-tuned with continuous monitoring of O₂ and CO.
• Fuel feeder minimum set point adjusted from 11% to 10%.
• Draft pressure corrected from -2.0 mmWC to -1.5 mmWC.
• On-site training provided to the team on EffiMax cleaning and tuning for sustained efficiency.

Boiler efficiency improved from 79% to 84%.

Feedwater temperature increased from 55°C to 60°C (131 to 140°F).

S:F ratio improved from 6.2 to 6.5 Kg/Kg (13.7 to 14.3 pounds/pounds).

Fuel savings of 4.8% achieved through burner fine-tuning and reduction in O₂%.

Blowdown TDS decreased from 4200ppm to 1591ppm.

Potential for further improvement of S:F ratio up to 6.7 by achieving higher feedwater temperature (75-85°C / 167-185°F).