Economizer Solutions by NBW, Inc.
An economizer is a boiler-mounted heat exchanger that captures waste heat from the exhaust stack to preheat boiler feedwater. By using recovered flue-gas heat, economizers reduce the fuel needed for steam generation. This lowers stack temperatures and fuel consumption, improving overall boiler efficiency. In fact, economizers can boost boiler efficiency by 3–5% in typical installations, with U.S. Department of Energy data showing waste-heat recovery can cut fuel use by up to 5–10% (often paying for itself within a couple of years). In practice, economizers preheat water leaving deaerators (typically ~225 °F) using exhaust gas (400–650 °F), maximizing energy recovery and reducing boiler thermal stress.
Services Offered
NBW specializes in expert economizer replacement solutions for industrial steam systems. Key offerings include:
- Replacement of aging units: We inspect failing or outdated economizers and recommend suitable new units. NBW’s engineers determine the correct model and help remove the old economizer and install the replacement equipment. This restores lost efficiency and heat-recovery capacity.
- New system sizing: For new boilers or plant expansions, NBW calculates and sizes economizers to match your steam load. Our design ensures the economizer has sufficient heat-transfer area and capacity to preheat feedwater efficiently. Proper sizing maximizes fuel savings and meets future process demands.
- Deaerator integration: Economizers work in tandem with deaerators to heat feedwater. NBW coordinates with leading deaerator manufacturers to integrate the economizer and feedwater system. This ensures feedwater temperatures and flows are matched, protecting deaerator performance and boiler safety. We help align the economizer outlet with deaerator inlet requirements for seamless operation.
- Engineering and support: Beyond equipment, NBW provides full engineering, layout and control integration. We assist with piping, instrumentation, and controls so the economizer ties into the boiler system cleanly. Our team can also retrofit economizers to existing boilers, optimizing space and access for maintenance.
Applications
Economizers are widely used in any industrial boiler application that can benefit from waste-heat recovery. Typical uses include:
- Power generation: Utility and cogeneration boilers use economizers to improve thermal efficiency and reduce fuel costs.
- Oil & petrochemical: Refineries, chemical plants and processing facilities commonly add economizers to reduce furnace stack losses.
- Pulp & paper: Mills rely on steam for processing and use economizers on recovery boilers to reclaim heat.
- Food & beverage: Steam-intensive operations (dairy, brewing, canning, etc.) employ economizers to preheat feedwater and improve sustainability.
- General manufacturing: Textile, pharmaceutical, electronics and other industries with large boiler systems use economizers for energy savings.
These sectors routinely install economizers on their boiler stacks to raise feedwater temperature and cut fuel use. For example, one equipment supplier notes economizers serve “refinery, utility, pulp or paper, food, [and] pharmaceutical… industries,” recovering heat from exhaust and returning it to process or feedwater.
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