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we can save more energy by the following
1- using the most hot flue gases in super heaters to increase the temperature of produced steam
2- using the the upper part of flue gases in economizers to heat the feed water before boiler entrance
3- taking heat from flue gases to preheat the air going to furnace
The best way to have boiler energy saving is to conduct boiler energy audit.
1. Boiler combustion system. air fuel ratio, fuel preparation, balance draft, excess oxygen analysis. all of these lead to fuel savings.
2.Boiler water, check water condition if it is free from hardness, check boiler water preparation mechanical and chemical process. this is very important , scale free boiler tube contributes boiler efficiency. Blow down as required, check steam pipe leaks, deffective steam trap. etc.
3.Check boiler insulations, heat transfer from boiler to the sorounding reduce overall efficiency.
4.Check boiler instrumentaion and controls. good boiler instrument and control contibutes energy savings.
5. Heat transfer area. check from time to time if tubes surface is free from soot and non combustible materials. Heat from combustion is transfer through tubes surface to working medium.Having clean tubes contribute to energy savings.
Hope this will help you.
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Rase feeding water and fuel temperature by collecting the flashes from your line.
Use steam trape and and condensate pumps to collect the condenste water and send it to water feeding tank.
Use thermal insulation for your steam distribution line.