Economizer

It is a product designed to increase energy efficiency and optimize fuel consumption in boiler systems. The economizer recovers a large portion of the heat released from the boiler's exhaust gases, providing an average efficiency increase of 4-6%. In addition, since the temperature difference between the water fed to the boiler and the evaporating water decreases, thermal stresses in the boiler are reduced, thus protecting your boiler. With the economizer, you can reduce your energy costs and experience the peace of mind of fulfilling your responsibilities to nature by reducing your carbon footprint.

Main Application Areas

• Boiler Flues (Steam Boiler, Hot Water Boiler, and Thermal Oil Boilers)
• Furnace Flues
• Gas Engines
• Process Flues

Features

• Available in Straight Tube and Finned Tube options.
• Easily removable cassette-type coil simplifies cleaning, maintenance, and inspection.
• Payback period of typically less than one year in most applications.

Key Considerations When Purchasing an Economizer

1. Flue Gas Automatic By-Pass Damper

The bypass damper is a critical control element used in economizers to manage flue gas flow. It is offered with two control options: pneumatic and electric actuators. As flue gas cools down to a certain degree, condensation can form, potentially resulting in unwanted acidic condensates depending on the flue gas content. In such cases, the bypass damper automatically activates to divert the flue gas directly outside, based on the economizer's designed temperature value, thereby protecting the economizer from unwanted effects. At FMT Boiler, the bypass damper is provided as a standard option for all economizers.

2. Proportional Feed Water Level Control

In a steam boiler controlled by on-off feed water control, the feed water pump stops when a sufficient water level is reached, cutting off the water flow. This lack of circulation causes the water inside the economizer to become stagnant. If the boiler continues firing while the water is stagnant, certain risks may arise. To prevent these risks and ensure efficient operation of the economizer, it is essential to maintain continuous water circulation and use a proportional feed water level control system in conjunction with a 3-way proportional control valve.

Condensing Type Economizer

Economizers are designed to reduce flue gas exit temperatures and save energy. As the flue gas temperature reaches the condensation temperature of the flue gas, acidic condensates may form. This can cause significant corrosion damage to the economizer, depending on the type of materials used. For example, the condensation of natural gas used in boilers generally results in the formation of sulfuric acid. To prevent such corrosion, the internal unit of the economizer is made from 316L-grade stainless steel seamless tubes, and the outer casing is made from 316L-grade stainless steel sheets. For more detailed information about condensing economizers and to find the most suitable solution for your process, please contact one of our sales engineers.

What is an Economizer and Its Role in Industrial Steam Boilers?

An economizer is a device designed to save energy by utilizing the waste heat from flue gases. In industrial steam boilers, it is used to preheat the feed water, meet hot air and hot water needs, and enhance energy efficiency in industrial plants by reducing costs and offering an environmentally friendly solution.

Advantages of an Economizer

• Energy Savings: By reusing the waste heat from flue gases, the economizer reduces fuel costs and minimizes environmental impact.
• Increased Efficiency: Improves the efficiency of industrial steam boilers, allowing more heat production with less energy.
• Cost Reduction: Lowers operating costs through energy savings, leading to significant long-term savings.
• Eco-Friendly: Reduces the carbon footprint by enhancing energy efficiency and causing less harm to the environment.

How Does an Economizer Work?

An economizer heats the feed water or air by using the waste heat from flue gases, thereby enhancing overall efficiency. Here is how an economizer functions:

1. Collection of Flue Gases: The economizer collects flue gases and utilizes their waste heat.
2. Heat Transfer: The heat from the collected flue gases is transferred to the feed water or air.
3. Heated Water or Air: As a result of the heat transfer, the feed water or air reaches the desired temperature and becomes ready for use.

Industrial Applications

Economizers are widely used in various industrial applications. Here are some examples:

• Food and Beverage Industry: Used to preheat feed water in steam boilers.
• Chemical Industry: Used to provide hot water required in production processes.
• Power Plants: Employed to increase efficiency in energy production.

Key Considerations When Selecting an Economizer

1. Needs Analysis: It is crucial to accurately analyze the plant's requirements when selecting an economizer. Determine which processes it will be used for and the necessary amount of heat recovery.
2. Capacity of the Device: The economizer's capacity should match the plant's steam or hot water needs. Insufficient capacity can reduce efficiency.
3. Ease of Maintenance: Regular maintenance of the economizer is essential for long-lasting and efficient operation. Ease of maintenance is an advantage.
4. Cost and Return: Consider the cost of the economizer and the energy savings it provides to calculate the investment's payback period.
5. Environmentally Friendly Features: It is also important to check whether the economizer is eco-friendly and reduces the carbon footprint.

By choosing the right economizer, you can ensure improved energy efficiency, reduced costs, and a more sustainable operation for your industrial facility.