I. Core Technologies of High-Efficiency Energy-Saving Steam Boilers
1. Fully Premixed Combustion Technology
This technology achieves complete combustion by precisely controlling the fuel-air mixing ratio. For example, the Bornd fully premixed condensing steam boiler uses imported European metal fiber burners, with the air-fuel ratio finely adjusted in real time by a servo motor. NOx emissions are consistently below 28 mg/m³, and the thermal efficiency reaches 103%. This technology reduces fuel waste and lowers pollutant emissions.
2. Condensation Recovery Technology
This technology utilizes the latent heat released by the condensation of water vapor in the flue gas to improve boiler thermal efficiency. The Liju vacuum condensing steam unit uses the vacuum phase change principle, operating at sub-atmospheric pressure with a thermal efficiency of 101%. The Bornd boiler is equipped with a corrosion-resistant aluminum-silicon alloy condenser at the tail end, further improving thermal efficiency at an inlet water temperature of 20℃. Condensation technology can reduce the exhaust gas temperature from 220-230℃ in traditional boilers to 140-150℃, significantly reducing heat loss.
3. Modular and Quick-Start Design
Modular boilers allow for flexible adjustment of the number of operating units based on load demand, avoiding the "oversized engine for a small load" phenomenon. For example, the Bornd 6 t/h model can produce steam in 3 minutes and reach rated pressure in 8 minutes, shortening the time by about half compared to traditional water-tube boilers, thus reducing standby energy consumption. The Wom fully condensing low-NOx steam generator has a water capacity of less than 30 L, requires no inspection, and is compact, making it suitable for rooftop or basement renovation projects.
4. Intelligent Control System
Automated operation is achieved through PLC or DCS systems, optimizing combustion parameters. Bornd boilers use a Siemens S7-1200 PLC, supporting the Modbus RTU protocol, which can seamlessly interface with the factory DCS to monitor parameters such as pressure and temperature in real time, automatically adjusting fuel supply and air volume to ensure the boiler operates under optimal conditions.
II. Energy-Saving Strategies for High-Efficiency and Energy-Saving Steam Boilers
1. Steam System Optimization
Steam cascade utilization: High-pressure steam is first used for power equipment, then depressurized for heating or warming, avoiding energy waste caused by high-pressure steam directly expanding into low-pressure steam.
**Blowout Heat Recovery:** Install blowout expansion tanks or heat exchangers to recover heat from boiler blowout, controlling the blowout volume to below 5%, ideally 2%. For example, recovering flash steam from the blowout using a flash tank to increase boiler feedwater temperature can save 1.28% of energy (at 10 barg pressure).
**Steam Trap Management:** Utilize expansion tanks to recover heat from steam traps, ensuring their normal operation. The condensate discharged from steam traps is of excellent quality, saving on water treatment costs after recovery.
2. **Pipeline and Insulation Design:**
**Pipeline Optimization:** Employ small-diameter pipes and short transport distances to reduce steam pressure drop. For example, reduce steam pressure to the minimum necessary value before transporting steam; if the pressure drop is large, utilize it for work.
**Insulation Material Selection:** Use materials with low thermal conductivity and good mechanical properties, such as expanded perlite and foam plastics. The surface temperature of the insulation layer should not exceed 55-60℃, and the economical thickness should minimize the sum of insulation costs and heat losses converted to fuel costs.
3. Fuel and Combustion Management
Fuel Selection: Prioritize clean energy sources such as natural gas and biomass pellets to reduce pollutants from coal combustion. For example, Xinli Boiler's SZW series biomass steam boilers utilize a double-drum longitudinal structure, offering high thermal efficiency and environmental friendliness.
Oxygen-Enriched Combustion Technology: By increasing the oxygen concentration in the combustion air, this technology promotes complete fuel combustion and reduces flue gas heat loss. This technology can improve boiler thermal efficiency by 5%-10%.
Regular Descaling: Scale buildup on boiler heating surfaces reduces heat transfer efficiency and increases fuel consumption. Acid washing descaling is recommended every 8000 hours of operation to maintain clean heating surfaces.
4. District Heating and Cogeneration
Regional Boiler Room Centralized Heating: Replace decentralized small boilers with high-efficiency, large-capacity boilers to reduce heat network transmission losses. For example, the district boiler room should have at least two boilers with a capacity of 10t/h, a heating capacity of over 50GJ/h, and a heating area of over 200,000 square meters.
Combined Heat and Power (CHP): Using turbine exhaust or extracted steam for heating reduces condensation losses. For example, converting a condensing power plant into a CHP plant can increase energy utilization by 40%-60%.
III. Application Cases of High-Efficiency and Energy-Saving Steam Boilers
1. Industrial Production Sector: A textile factory replaced its traditional coal-fired boiler with a Bornde fully premixed condensing steam boiler. This reduced steam consumption per ton of steam from 65 Nm³ to 59.1 Nm³, saving approximately 200,000 yuan in fuel costs annually. Simultaneously, NOx emissions decreased from 150 mg/m³ to 28 mg/m³, meeting environmental protection requirements.
2. Heating in Commercial Complexes: A large shopping mall uses modular condensing boilers for centralized heating. The system automatically adjusts the number of operating boilers based on daytime and nighttime load changes, avoiding energy waste during low-load nighttime periods. The system's thermal efficiency reaches 98%, saving more than 15% energy compared to traditional boilers.
3. Food Processing Industry
A food factory utilizes a steam cascade utilization system, first using high-pressure steam for sterilization, then depressurizing it for cleaning and heating. This increases steam utilization by 30% and saves approximately 100,000 yuan in steam costs annually.
IV. Future Development Trends
* Ultra-low emission technology: With increasingly stringent environmental requirements, NOx emission limits for boilers will be further tightened. Future technologies will focus on more efficient combustion control and exhaust gas treatment, such as the application of catalytic reduction (SCR) technology.
* Hydrogen boiler R&D: Hydrogen energy, as a zero-carbon fuel, is an important development direction for the boiler industry. Currently, some companies are conducting hydrogen combustion trials, and commercial application is expected within the next 5-10 years.
* AI-optimized control: Combining big data and artificial intelligence technologies, real-time optimization of boiler operating parameters can be achieved, further improving energy efficiency. For example, machine learning algorithms can predict load changes and adjust fuel supply in advance.
