Industrial boiler load refers to the ratio of the actual output of steam (or hot water) heat from the boiler to the rated output heat.Is one of the core parameters to measure the operating status of industrial boilers.

Load adjustment is achieved by increasing or decreasing fuel volume and air volume.Load fluctuations can cause abnormal steam pressure and temperature, cause burst pipes of pressure-bearing components, and reduce thermal efficiency and accelerate equipment aging.Low-load operation can easily cause unstable combustion, local over-temperature of the heating surface and low-temperature corrosion of the tail pipe.

1.Boiler load classify:

*Rated load: The boiler is at the pressure and temperature specified by the design.

*Actual Load: The output of the boiler during operation.

*Economic load: Usually 70%-90% of the rated load. The boiler has the highest thermal efficiency and the most fuel consumption in this range. It is the preferred recommended operating range in industrial production.

*Low load: The load rate is less than 50%. At this time, the combustion of the boiler is unstable and the thermal efficiency is greatly reduced. Problems such as furnace coking and high exhaust temperature may also occur. Long-term low-load operation should be avoided as much as possible.

2.Factor affect boiler load :

*Demand variation: Industrial processes rarely have constant heat needs; loads change daily, seasonally, or by production cycle.

*Rated load and actual load: The rated load is the maximum design output, and the actual load is the actual use.

*Load management: Strategies to match generation with demand using automation, forecasting, and coordinated boiler operation to improve efficiency.

3.Purpose of load adjustment

*Efficiency: Keeps boilers in their optimal operating range, reducing fuel waste.

*Reliability: Prevents shutdowns from sudden demand changes or issues from prolonged low-load operation.

*Cost Savings: Lower energy consumption and operating costs.

*Longevity: Reduces wear and tear from rapid cycling.

4.Problem during load adjustment

*Incomplete fuel combustion: May cause the furnace to explode.

*Temperature exceeds the standard: May damage the superheater and steam pipe

*The water level fluctuates sharply: There is a sound of water strike in the steam pipe.

*Auxiliary machine tripped and stopped: Boiler stopped working.

5.Method of load adjustment:

*Load adjust should not be too fast, otherwise it will cause severe fluctuations in furnace pressure and steam pressure, affecting the safety and stability of the boiler.

*When increasing the load, the fuel supply and air supply need to be increased at the same time to ensure that the fuel is fully burned.

*When reducing the load, the fuel and air volume are reduced synchronously to avoid hypoxic combustion or excessive air coefficient.

*During long-term low-load operation, layered combustion and air distribution optimization can be used to improve combustion stability and reduce heat loss.

Conclusion:

The key to the load adjustment of industrial boilers lies in “precision, stability, and matching”, through standardized operation procedures, and early failure prevention and control.Ultimately improve operating efficiency and reduce energy consumption.