5 Reasons Why Your Boiler Is Consuming Too Much Fuel

5 Reasons Why Your Boiler Is Consuming Too Much Fuel

Boiler efficiency and energy/fuel consumption can account for a large proportion of a plant’s utility cost. In fact, it is said that the initial cost on the boiler is only fifteen percent or less compared to the fuel cost in a life span of the boiler. So, the right selection of a boiler is very crucial for any industry.”

In general, the design of your boiler is imperative. Even so, there are several other
environmental factors that impact the efficiency of your industrial boiler. Understanding what they are will help you recognize shortcomings in your boiler, which will empower you to resolve these issues and put your system on the fast path toward optimization.

Conducting a thorough evaluation of your boiler system may reveal opportunities for substantial savings. Your review should include a look at your boiler’s operation, its fuel usage patterns, and improvements that can be made.

Reasons for more fuel consumption

1. Excess Air Effect on Industrial Boiler Efficiency

A combustion chamber is supplied with excess air in order to ensure that the fuel is
completely burned. Oxygen is added to the combustion process and fuel is burned faster when there is excess air. Stoichiometric combustion occurs when fuel and oxygen from the air are in perfect balance. As combustion efficiency increases with excess air, the heat loss exceeds the heat provided by more efficient combustion.

By controlling the flame temperature, ultra low-emission burners minimise the production of NOx and carbon monoxide.

The excess air ultimately absorbs a portion of the heat from combustion. As a result, it reduces the efficiency of the transference of heat to the water in the boiler. This issue may be addressed by calibrating the boiler at multiple firing levels and regularly.

2. Flue Gas Temperature

As the combustion gases leave the boiler, they reach something called the “stack
temperature level” or flue gas temperature level. Having a high level of flue gas temperature suggests that your boiler is not creating steam efficiently. Simply put, more the flue gas temperature level, more heat is being lost.

When aiming to attend to heat loss via high flue gas temperature levels, it typically includes setting up combustion air heating units or setting up economizers. These techniques are created to recuperate heat for the boiler system

If the boiler depends upon biomass, coal, or other strong fuels, it’s likewise vital to consist of a routine boiler list or upkeep program. Boiler upkeep will guarantee the system is running effectively and make certain that the surface areas of heat transfer inside the boiler are tidy.

3. Convection and Radiation Losses

Convection and radiation losses are the losses of heat originating from the boiler throughout basic operation. Put simply, one cannot do much regarding the convection & radiation loss since they’re unavoidable. Despite the fact that they’re inescapable, you can take the ideal actions to reduce them

Two of the best and reliable techniques for decreasing loss via convection and radiation are:

1) Setting up remarkable insulation
Managing the air flow over the boiler surface area
When you use appropriate insulation techniques, you will strengthen commercial boiler effectiveness by reducing heat losses and lowering surface area temperature level.

2) Protecting it from indoor drafts and outside winds
This avoids the loss of heat triggered by air streaming over the boiler surface area.

4. Fuel Specification

As practically anybody would anticipate, sustain requirements can have a remarkable result on your commercial boiler effectiveness. Resolving this problem is as easy as developing the appropriate specs for fuel and ensuring the real fuel fulfils the paperwork requirements.

Due to the high material of hydrogen for commercial boilers counting on gas, fuel
requirements ought to be of the utmost significance. It’s crucial to comprehend that a substantial part of the hydrogen is changed into water throughout combustion. This procedure can monopolise energy, which might be more appropriately utilised in the procedure of combustion.

The main flammable in gas is (CH4) / methane. There are numerous lower traces of:

Pentane (C5H12).
Ethane (C2H6).
Butane (C4H10).
Gas (C3H8).
In Short, the more the material of hydrogen (H) in the combustion gases, the higher the amount of water produced through combustion. Put simply, gases with greater methane concentrations will burn a lot more effectively.

5. Surrounding Temperature

The temperature level of the combustion air going into the boiler is called the surrounding or ambient temperature level. Another meaning for ambient temperature level is the temperature level of the air urged by the forced draft fan. Irrespective of how you specify it, ambient temperature level can have a fairly obvious impact on commercial boiler effectiveness.

Attaining the maximum balance is a fragile scenario that includes tactical factors to consider. Most commercial boiler effectiveness estimations recommend you attain an ambient temperature of 70 ° or 80 ° Fahrenheit.

It’s appealing to reduce the ambient temperature level with hopes of reducing flue gas temperature, a 40 degree modification in ambient temperature level can impact commercial boiler effectiveness by one percent or more.

As the combustion gases leave the boiler, they reach the “stack temperature level” or flue gas temperature level. Having a high flue gas temperature level shows that the boiler is not creating steam efficiently. Due to the high material of hydrogen for commercial boilers relying on natural gas, fuel spec needs to be of the utmost value. The temperature level of the combustion air going into the boiler is called ambient temperature level. Regardless how you specify it, ambient temperature level can have a reasonably obvious impact on commercial boiler performance.

With respect to the above points, here are some ways to Increase Fuel Savings in
Simply a modest enhancement in boiler performance can lead to substantial fuel cost savings.

It can likewise have an effect on commercial boiler effectiveness computations due to it impacting the net stack temperature level. Net stack temperature level is the distinction between the flue gas temperature and the ambient temperature level.

  • Excess Air Reduction
  • Insulation of Boiler
  • Automatic Boiler Blowdown
  • Setting Up Stack Heat Recovery Systems
  • Setting up blowdown Heat Exchangers

And last but not the least, the best method to keep your commercial boiler system running securely and effectively is to carry out a properly designed boiler maintenance program.

As a leading manufacturer of high quality and sturdy boilers with a worldwide customer base, at Shanti Boilers we make it our service to supply our consumers with the greatest level of service together with effective, reputable and ingenious heating options.