The problem of excessive fuel consumption in boilers
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For natural gas boilers, when the load is only 30% of the rated value, the gas consumption remains at the level corresponding to the rated operating condition. May I ask what the reason is?
I’d like to add that it is a 15 t/h gas-fired superheated steam boiler; the feedwater flow meter indicates around 7 t, while the steam flow meter shows just over 5 t. The gas flow meter shows 1200 Nm3/h; since the water supply volume and steam volume are roughly equal, there should be no problem. Could it be that the gas flow meter is inaccurate, but the client says there is no problem with it? Theoretical calculations show that to reach 15 tons of steam, only 1250 Nm3 of gas is required – the difference is absolutely enormous. The boiler is a newly installed one, and it has just started operating. Could someone with expertise help analyze this? Thank you
Steam boilers seem to be most economical at 80% load.
Conduct an energy efficiency test, and the problem can be identified!
It is recommended to check: excess air coefficient (whether oxygen level is excessive)； Install a water meter on the desalinated water feed main (to verify that the water supply volume is correct and to rule out any discrepancies) ； The issue of gas flow rate can be addressed by determining the approximate flow rate based on pressure loss, in combination with the pipe diameter and length (it is necessary to know parameters such as the gas density and viscosity, and to refer to relevant calculation standards) ； Is the exhaust temperature exceeding the limit? ； If possible, measure the airflow for ventilation and exhaust.
It has just started running; of course it is like that. How long has it been running? When the engine is first started, the burner operates at full load and no steam is produced. It takes some time for steam to be generated, and water is added gradually. At the very least, the water within the system must first be heated to the target temperature before steam can be discharged outward.
Thank you:handshake
The runtime is very short, less than 2 or 3 hours. I’m currently debugging the burner; let’s run it for a longer period of time and see. Thank you.