The combustion boiler is at the heart of many operations. Whether it’s a power boiler operating in a combined heating plant or a recovery boiler in a pulp and paper mill. They enable processes to run smoothly and efficiently if maintained right. The boilers have a universal enemy that not only affect their efficiency but also the bottom line– fouling. One of the most overlooked consequences to heavy fouling Is increased fuel consumption. It is therefore important to mitigate the issue before the consequences get unbearable.

 

Why does fuel consumption increase due to fouling?

The overall performance of the boiler relies heavily on efficient heat exchange. The heat must flow from combustion chambers to water, generating steam that is essential for different processes in the combustion plant. The deposit buildup on boiler surfaces disturbs the heat exchange, this notion is well documented and fairly agreed upon. The hidden culprit though, is that in order to maintain the same steam output levels, pushing through more fuel is required.

 

The toll on operations

The consequences of fouling and thus fuel, goes beyond more expensive fuel bills. The resources that are allocated toward maintaining the same steam output could prove to be needed elsewhere which impacts the business profitability.

 

Environmental

Being a company, passionate about clean tech, we couldn’t write an article on this topic without bringing up the environmental implications of a heavily fouled boiler. Putting the economics aside, with more fuel input to overcome performance barriers, emissions increase. Making the decision to mitigate the fouling issues of your boiler will therefore not only be beneficial to the organisations budget, but also contribute to a greener tomorrow.

 

Mitigate the fouling

Addressing fouling requires a proactive approach. Regular maintenance, timely cleaning, and preventive strategies are essential. Among these strategies, the High Impact Sootblowing System by Heat Management emerges as a game-changer. The High Impact Sootblowing System (HISS) has been installed at numerous satisfied reference sites with amazing results, either by increasing the boiler load, or improving boiler efficiency, without consuming any more steam. Or by reducing steam consumption by 30-50% while keeping the same load as before the installation. The nature of HISS allows for one-way sootblowing and the first stroke makes up for 90% of the cleaning effect. By also incorporating overlapping sootblowing, where the lances overlap instead of the traditional alternating starts, there will be efficient cleaning with reduced total time per cycle.

 

Conclusion

Being the backbone of several industries, the boilers drive the business forward. It is essential to understand the challenges they face whether it is for recovery boilers or power boilers.

Fouling contributes to an increase in fuel consumption which in turn affects environmental and financial aspects of the plant or mill. HISS takes an immense load off user’s shoulders when it comes to remaining proactive in a never-ending battle against fouling.

Let’s embrace innovative solutions to move us forward to cleaner operations and reduced fuel consumption.