Modification of the flow pattern in ducts outlet and economizer chamber for optimization of existing high pressure boilers to improve boiler performance

Industrial steam boilers play a pivotal role in various processes across industries, consuming significant energy resources. Enhancing the energy efficiency of these boilers is of paramount importance in the current scenario of energy conservation. This paper presents a comprehensive study on the upgrading of existing boilers ducts by incorporating an additional economizer, facilitated by thermal and draft calculation study. The existing ducts which are at service for a long time will be substituted by the new one with consideration of technical investigation. The primary focus is to enhance the efficiency of conventional boilers by optimizing the heat transfer process through the newly added economizer. The paper outlines the methodology employed for analysis, modeling, and simulation of the flue gas ducts, presents Fluent -generated results, and discusses the implications of the findings on overall heater efficiency. In this direction, in order to study and design the optimal mode of ducts to prevent operational difficulties and optimal operational performance conditions, various plans are examined and the best method is selected for boilers optimization. In total, for five boilers, it reduces fuel consumption and pollutant emissions by 47,000 tons and 1.7 million tons, respectively, in one year. In addition, the social cost of carbon is also reduced by 3.3 million dollars per year. Therefore, by using the new economizer, while increasing the efficiency of the boiler, significant energy savings are achieved. In this regard, the cost of fuel consumption is reduced and environmental pollutants are also significantly reduced.