Boiler Economizer: What You Need to Know

Boiler economizers are designed to capture excess heat. Instead of wasting this heat, the boiler economizer recovers it and uses it to optimize the boiler’s overall efficiency. Economizers capture thermal energy that would otherwise be wasted. These heat exchangers transfer heat from flue gases to the boiler feedwater. 

Boiler economizers are very effective at reducing energy consumption and minimizing waste. These heat exchangers can also be used for tasks like preheating fluids. So, what is an economizer in a boiler? Here’s everything you need to know about boiler economizers.

What is a Boiler Economizer?

Boilers can be used for a wide range of industrial applications, including heating. However, if boilers aren’t efficiently designed, excess heat can escape with exhaust gases. Thankfully, there’s a more efficient way to design the exhaust stack and limit the loss of thermal energy. 

Economizers are a fabricated assembly of finned tubing that trap waste heat from the flue gases emitted by the boiler’s stack. Boiler economizers can be installed to recover the exhaust waste heat. In turn, economizers reduce the amount of fuel the boiler needs to produce steam and limit pollution.

What Does an Economizer Do in a Boiler?

Boiler economizers are heat exchangers that transfer heat from the flue gas to another area. It’s usually used to heat the boiler feedwater. These devices improve indoor air quality by improving ventilation. In addition, using a boiler economizer can improve energy efficiency and lower operating costs. 

How Does a Boiler Economizer Work?

Boiler economizers work by trapping heat from the exhaust flue and channeling it to the boiler by heating the feedwater. By using the existing feedwater and heating it, the boiler minimizes the amount of fuel needed to convert the feedwater into steam. Fuel efficiency is a key concern for boilers, and a boiler economizer can lower costs, improve efficiencies and support a cleaner environment. 

Types of Boiler Economizers 

There are two primary types of boiler economizers: condensing economizers and non-condensing economizers. Here are some of the key features of each type: 

Condensing Economizers

According to the U.S. Department of Energy, companies can improve steam system efficiency by up to 10% if they install a condensing economizer. 

Condensing economizers cool recovered heat to a temperature below its dew point. These economizers can work for corrosive fluids and are designed to capture a large amount of heat. These economizers are most effective when low-temperature heat sinks are employed to lower the flue gas temperature well below the condensing temperature.

Non-condensing Economizers

This type of economizer is the most commonly used. Finned heat-exchange coils are placed in the flue gas ducting at the boiler’s exit. Non-condensing economizers can raise a boiler’s overall efficiency by close to 4%. 

With this design, the flue gas temperature stays above the condensing point, so the flue gas ducting isn’t damaged by corrosion. This design is ideal for operations that use sulfurous fuels. 

Benefits of Boiler Economizers

Boiler economizers present many benefits for companies. From sustainability to fuel efficiency and reduced operating costs, there are several reasons to consider boiler economizers for your operations. Here are a few reasons you should consider adding them to your boilers:

  • Improve your boiler’s efficiency by anywhere from 2-10%
  • Reduce excess heat loss
  • Improve fuel efficiency and reduce fuel costs
  • Conserve between 5-12% of your boiler’s energy output
  • Promote sustainability and improve air quality
  • It recovers more heat from flue gases than traditional air preheaters

Boiler Economizer Manufacturers

Adding a boiler economizer to your operations can lower operating costs, improve fuel efficiency, limit waste and improve ventilation and air quality. However, special care should be taken when designing boiler economizers and sourcing and manufacturing these devices. Premium-grade boiler economizers can support your operations and protect your investment for years to come. 

Industrial Boilers of America: Your Top Choice

We are a leading boiler economizer manufacturer with over 20 years of industry experience. Our devices are designed to recover greater enthalpy, improve efficiencies and promote sustainability. 

Every boiler economizer needs to be meticulously fitted with the proper flue gas volume, temperature, gas type, and pressure drop that will be allowed through the stack. 

We design each boiler economizer for our customers’ unique needs and keep cost-effectiveness and operational efficiency at the forefront of these decisions. As a result, you will see the difference in our innovative designs and long-lasting materials. We deliver sustainable, low-cost solutions for all of your company’s needs. 

Contact Industrial Boilers of America to get a quote for your project. 

Industrial Boilers America

At Industrial Boilers America, we lead in providing the development, licensing, and deployment of Industrial Power plants. We partner with other leaders of communities and governments to foster long-term relationships that create sustainable energy, jobs, and social responsibility. Our philosophy that sustainability should be rooted in the betterment of the ecosystem rather than profit allows us to provide services that will enable our partners to reinvest in themselves, resulting in a sustainable community.

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