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Optimizing efficiency and reducing energy loss

Modernization of plants

Modernisierung von Kesselanlagen

Dealing responsibly with fossil fuels is more important than ever today. It follows that a modern combustion plant must extract as much output power as possible from the available fuel. This requires a high level of efficiency. That's why you should optimize your plant with modernization modules from SAACKE!

The SAACKE portfolio includes:

  • Speed-controlled motors
  • CO/O2 controllers
  • Economizers and heat exchangers
  • Calculation of the potential for reducing costs and emission with the SAACKE Energy Efficiency Calculator
  • Optimization of operating mode and controller parameters

Precise speed controllers for all burners

One optimization measure for combustion plants that are operated at partial or low load are SAACKE speed controllers. They reduce the speed of the combustion air fan if the burner does not need the full air flow, thus saving valuable energy.

Speed controllers from SAACKE have many advantages: They can be used on all types of burners and heat generators, can be easily retrofitted and improve control response, especially in the low load range. Significantly lower running and operating noise are not just welcome news for ears: Fan and burner components also benefit from low mechanical load. The main argument for SAACKE speed controllers, however, is the minimizing power consumption: Savings of up to 80% compared to plants without control speak for themselves.

Effective O2/ CO control

The SAACKE O2 control measures the actual oxygen content in the flue gas and ensures that the fuel/air ratio is always constant. This makes it possible to improve the efficiency of your combustion plant by about 1-2% compared to a conventional combustion plant with increased air excess.

This optimization measure, which can easily be installed in new and existing combustion systems, has various advantages: It is suitable for all standard fuels and heat generators, is low-maintenance and has a long service life. Continuous limit value monitoring decisively improves plant reliability and safety. Since O2 control eliminates fluctuations in the fuel and combustion air, minimizes O2 surplus at each firing rate and has a very short response time (t < 15s!), the average amortization time is less than two years.

A CO probe can be added to oxygen control with speed-controlled gas burners. This combination of two SAACKE solutions allows for operation close to the CO limit.

The seavis efficiency monitor

SAACKE is highly involved in optimizing the efficiency of industrial combustion plants. We offer you the opportunity of calculating the potential savings of your plant in electrical and fuel costs and for lowering emissions with the seavis efficiency monitor. This solution developed by SAACKE collects specific information about your plant regarding operating hours, load distribution, fuel data, burner starts as well as numerous other general data points. Optimization measures are then described with resulting savings. The results of the calculations are displayed compactly and transparently. Investments and savings are compared clearly and concisely.

The seavis efficiency monitor gives you an overview of potential optimizations, investments associated with them and amortization times, all simply simulated so that you can quickly estimate which investments are most practical for your plant.

SAACKE heat exchangers and economizers

To make use of the valuable energy that is normally lost with the flue gases of a plant, SAACKE offers heat exchangers and economizers as modernization measures for your plant. They can increase the efficiency of a plant by up to 11% while simultaneously lowering emissions considerably. Both components can be used on water-tube boilers and shell boilers and they can be operated with all standard fuels.

The SAACKE economizer is especially suitable for all types of steam boilers to preheat the boiler feed water and hot water generators to raise the return line temperature of the heat circuit. Control can be adapted to requirements with the appropriate flue gas dampers and easily retrofitted into existing plants.

Air preheating is the optimum alternative when media are available at a low temperature level too infrequently or irregularly to make use of an economizer practical. With an air preheating system the energy from the flue gases is used to preheat the combustion air of the burner. Thermal oil heaters are ideally suited for air preheating due to their high temperature level.

What does efficiency optimization mean?

The efficiency of a plant is adversely affected to a significant extent by various types of heat loss, for example by radiation loss, continuous blow-out loss or desludging loss and especially by flue gas loss. The best way to optimize efficiency is to reduce flue gas loss.

The determining factors in this case are the flue gas temperature and air excess: Since hot flue gas gives off a great deal of unused energy into the environment, SAACKE has developed solutions to lower the flue gas temperature, thereby reducing heat loss. The air excess is the difference between the amount of combustion air actually set and what is theoretically necessary. If the air excess is too high, valuable unused heat will be lost. SAACKE therefore offers efficiency analyses and optimization of controller parameters.