Your sending a whole lot of energy out of your system and taxing it more on heat up. There’s a old time saying in Maine with energy company’s. “ On the coldest day of the year your system shouldn’t turn off”. “It’s sized right”. (Most techs will way over size systems to make up for their lack of expertise to make the sale). Now most customers thought that they were wasting fuel and that was a tuff battle to over come. So we would increase the nozzle size or orifice on the boiler and then it would not run as long (but cycle more) and this pleased them. Albeit for just a month or two and then the calls would start. “Why is our bill so high”. Did you raise our price? We say no you wanted us to de-tune your system so it wouldn’t run so long. And then so we go out and re-tune it to the way we do it and tell them if you don’t save money your service calls are on us for a year. Never have done a refund. Go figure? Remember, long an slow is always better than short and fast!
Its not over thinking it, it’s dialing it in for the best efficiencies in energy (money) and system longevity (money). I rather spend $$$ on grains and barrels than gas and boilers even having the luxury that we charge the distillery jobbers cost on everything. Just comes out of the other pocket.
Ps if your system only runs 50% of the time you may want to change out the gun on your boiler. The pay back should be less than 2 years for something that should last 8-10.
BTW, We run a 500,000 BTU modulating steam boiler with a 4” header. This supply’s a 275 gal stripping still a 109 gal spirit still and a 275 steam injected kettle. Every thing runs 7 Day’s a week. We use 225 to 275 gal of LPG a week depending on season (2” globe valves on everything for adjustment).
First thing we get the spirit charged and running (1 hour heat up and 5.5 hour run). Meanwhile fill the kettle and bring up to temp while the spirit still is heating up. Turn off the steam educator on the kettle and then turn on the stripping still. (1 hour heat up and 4.25 hour run). The boiler stays between 7# & 12# (we might reduce to 11#) bouncing between low and high fire and doesn’t shut off throughout the day. And our returning condensate pipe is typically warm not hot.
And believe it or not we are up grading to 750 gallon stripper and kettle and 275 spirit still starting next month and the same 500,000 BTU boiler will do it. Staging will change a bit and our still run times will increase 1.5 hours and our total cook time will go to 6 hours from 4.5 hours. It’s all in a day and if my math and heat loss calculations are off we’ll just install a Rinnai wall hung that we can re-chip to provide 180* water for the kettle with a fill time of 1 hour. Worth every penny of $1500 vs 35k for for a bigger boiler.
Frugality marches on .