CONTENTS

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2.
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9.

Introduction to Economizer
Roll of Economizer on Boiler
Types of Economizer
Advantages of Economizer coil
Design Calculation of
Economizer coils
Drawing of Economizer coil
Quality plan for manufacturing
of Economizer coil
Fabrication of Economizer coil
Conclusion

Introduction to Economizer:

Economizers (US and Oxford spelling),

or economisers (UK), are mechanical devices
intended to reduce energy consumption, or to
perform another useful function such as preheating
a fluid. The term economizer is used for other
purposes as well. Boiler, power plant, heating,
ventilating, and air conditioning (HVAC) uses are
discussed in this article. In simple terms, an
economizer is a heat exchanger.

An economiser is a mechanical device which is used

as a heat exchanger by preheating a fluid to reduce
energy consumption. In asteam boiler, it is a heat
exchanger device that heats up fluids or recovers
residual heat from the combustion product i.e. flue
gases in thermal power plant before being released
through the chimney. Flue gases are the combustion
exhaust gases produced at power plants consist of
mostly nitrogen, carbon dioxide, water vapor, soot
carbon monoxide etc. Hence, the economiser in
thermal power plants, is used to economise the

process of electrical power generation, as the name

of the device is suggestive of. The recovered heat is
in turn used to preheat the boiler feed water, that will
eventually be converted to superheated steam.
Thus, saving on fuel consumption and economizing
the process to a large extent, as we are essentially
gathering the waste heat and applying it to, where it
is required. Nowadays however, in addition to that,
the heat available in the exhaust flue gases can be
economically recovered using air pre-heater which
are essential in all pulverized coal fired boiler.

Role of economizer in boiler

In boilers, economizers are heat exchange

devices that heat fluids, usually water, up to but not
normally beyond the boiling point of that fluid.
Economizers are so named because they can make
use of the enthalpy in fluid streams that are hot, but
not hot enough to be used in a boiler, thereby
recovering more useful enthalpy and improving the
boiler's efficiency. They are a device fitted to a boiler

which saves energy by using the exhaust gases

from the boiler to preheat the cold water used to fill it
(the feed water).

Energy heat recovery with condensing economizer.

The boiler room is a huge energy guzzler. It
consists of thermal fluid boilers or steam boiler, with
exhaust gases through a common chimney. An
indirect contact or contact condensing economizer
will recover the residual heat from the combustion
products. A series of dampers, an efficient control
system, as well as a ventilator, allow all or part of the
combustion products to pass through the
economizer, depending on the demand for make-up

water and/or process water. The temperature of the

gases can be lowered from 200C to 10C, while
preheating the process water from 8C to 80C. On
average over the year, boiler combustion efficiency
has risen from 80% to more than 95%. The
efficiency of heat produced is directly linked to boiler
efficiency. The percentage of excess air and the
temperature of the combustion products are two key
variables in evaluating this efficiency.

Types of Economizer
CI Gilled Tube Economizer
The gilled tube economizers are made up of cast
iron which are fabricated using graded cast iron fins,
have following features,
High optimum efficiency due to proper contact of
gills with tubes.

 Commonly used in plants where intoxicated flue

gas is generated due to the quality of fuel burnt.
Round Gilled Tube Economizer
This is made by mild steel fabricated with square
and round fins, welded on carbon steel seamless
tubes, have the feature,
Proper contact between the tubes and fins are
ensured for optimum efficiency.
Coiled Tube Type Economizer
These are used mostly in thermal power plants and
large processing units. These coiled tube type
Economizers are fabricated out of carbon steel
seamless, have following features,

These are very efficient in recovering the heat

from gases.
Occupy very little space.
Horizontal Finned Tube Economizer
In this is carbon steel seamless tube sealed
welded with horizontal fins to make a complete

assembly of economizer for heat transfer, have

following features,
Proper care is taken for making the contact of
fins with tubes for perfect heat transfer.
These are used mainly used by Thermal Power
Plants.

Advantages and Benefits of Economizer

It recovers more heat of flue gases which normal
air pre-heater cannot do.
Due increase in fuel prices, all power plants are
facing pressure for increasing boiler efficiency.

So by using economizer, this pressure can be

minimized.
Power plants where it is not used, large quantity
of water is required to cool the flue gas before
desulphurization which is minimized by using
Economizers.
The efficiency of power plant reduced when
steam air pre-heater required steam.
There is an increase in efficiency of the steam
power plant.
Erosion of turbine blade is minimized (or) even
eliminated.
Steam consumption
reduced.

of

the

prim-mover

is

Condensation loss in the pipes is reduced.

It removes entrained water particles from the

steam conveyed to the steam turbines and
increases the temperature of saturated steam.
Design Calculation of Economizer coil:

Drawing of Economizer coil:

Quality Plan for Manufacturing of

Economizer coil:

Fabrication of Economizer coil

Conclusion