Economizers

What is an Economizer?

Simply put, an economizer is a heat exchanger that recovers waste heat in boiler systems. The hot flue gases generated by combustion in boilers are used for preheating through the economizer before being discharged into the atmosphere through the chimney. Thus, usable heat energy is not lost, and the overall efficiency of the system increases.

How Does an Economizer Work?

It transfers the high-temperature energy from the flue gas to the water, preheating it. This process consists of the following main steps:

1. Combustion and Flue Gas Formation: High-temperature flue gases are produced as a result of fuel combustion inside the boiler.
2. Gas Flow: These flue gases move toward the chimney.
3. Heat Recovery: As the flue gases pass over the heat transfer surfaces (pipes, etc.) in the economizer, they transfer their heat to the water flowing through them.
4. Preheated Water Enters the Boiler: The preheated water exiting the steam boiler economizer is used as boiler feed water. Thus, less fuel is required to heat the water inside the boiler.

What Are Its Advantages?

1. Increased Energy Efficiency: By recovering heat from the hot flue gases, the feedwater is preheated, allowing the desired steam pressure and temperature to be reached with less fuel consumption.
2. Fuel Savings: Economizers reduce the fuel consumption of the boiler, lowering operating costs and increasing profitability.
3. Reduced Carbon Footprint: With less fuel consumption, the amount of CO₂ emissions to the atmosphere also decreases, contributing to environmental sustainability.
4. Extended Equipment Life: Preheating reduces thermal shock to the boiler. This prevents unnecessary expansion or contraction in boiler tubes and other parts, extending equipment life.
5. Efficient Production Continuity: Increased system efficiency helps ensure that production processes continue more stably and sustainably.

What to Consider When Selecting a Product?

• Boiler Capacity and Operating Conditions: In designing the economizer, the boiler’s steam production capacity, operating pressure, and temperature values must be considered.
• Gas Flow Rate and Temperature: The flow rate and temperature range of the flue gas play a critical role in system design and material selection.
• Material Quality: High temperatures and corrosive gases can cause deformation or corrosion in the pipes. Therefore, high-quality and process-appropriate materials must be used.
• Insulation and Installation: Proper insulation and installation of the economizer minimize heat losses and help achieve maximum efficiency.
• Ease of Maintenance: Factors such as maintenance intervals, ease of servicing, and spare part replacement are crucial for efficient and long-term use.

Types of Economizers

1. Shell & Tube Economizer: The most commonly used type. The flue gas passes outside the tubes, while the water flows inside (or vice versa). It offers high temperature and pressure resistance.
2. Finned Tube Economizer: Fins are added to the tubes to increase the heat transfer surface area, aiming to extract the maximum possible heat from the flue gases.
3. Plate Economizer: A type where heat transfer occurs between fluids passing through plates. It provides space-saving advantages due to its compact design but is less preferred in high-pressure applications.

Energy Efficiency and Sustainability

Improving energy efficiency not only reduces operating costs but also minimizes environmental impact. Today, many industrial organizations prefer energy-saving technologies like economizers to reduce carbon emissions and build a greener future. In this regard, steam boiler economizers form a key part of a sustainable business approach.

Hisarmak Industrial Boiler Systems

At Hisarmak Industrial Boiler Systems, we offer solutions for all types of boilers and heat recovery systems needed in the industry, backed by years of experience and a professional team.

• Design and production of economizers tailored to your processes
• On-site inspection and expert consultancy
• Manufacturing of long-lasting equipment with high-quality materials
• Periodic maintenance and after-sales technical support

Thus, you can enhance your energy efficiency while getting one step closer to your environmentally friendly production goals.

Economizers are one of the most effective technologies for increasing efficiency and reducing operating costs in industrial boiler systems. Recovering the heat energy lost in flue gases contributes to lowering fuel expenses and reducing environmental burden. A properly selected and designed economizer greatly supports your business in achieving both economic and sustainability goals over the long term.

As Hisarmak Industrial Boiler Systems, we are at your service for any heat recovery project and economizer solutions you may need. You can contact us to enhance your energy efficiency and reduce your operational costs and get detailed information and consultancy from our expert team.