5 Factors Affecting Industrial Boiler Efficiency

Posted on March 31, 2015

When calculating industrial boiler efficiency using the ASME Energy Balance Method, one needs to account
for stack losses, radiation losses, and convection losses. But what are the factors that affect these readings
and, ultimately, boiler efficiency?
An obvious answer is the design of the industrial boiler itself. But there are also a host of environmental
factors that can impact boiler efficiency calculations. Knowing what they are will help you identify
shortcomings in your boiler system so you can resolve them and put your system on the path to
optimization.

1. Flue Gas Temperature

Flue gas temperature, also known as stack temperature, measures how hot the combustion gases are as
they exit the boiler. If the temperature of the flue gas is high, it indicates that heat produced by the boiler is
not being used to create steam and is therefore being lost.
Addressing heat loss through high flue gas temperatures often involves installing economizers or
combustion air heaters to recoup heat for the boiler system. In the case of boilers that depend on solid fuels
(e.g., coal, biomass), its also important to implement a regular maintenance program to make sure that the
heat transfer surfaces in the boiler are clean and operating efficiently.

2. Fuel Specification
It shouldnt come as any surprise, but boiler fuel specification can also have a dramatic effect on efficiency.
Addressing this issue is simply a matter of establishing the right fuel specification and ensuring that actual
fuel meets the documented criteria.
Fuel specification should be of particular concern for industrial boilers that rely on natural gas, due to the
typically high hydrogen content. Some of this hydrogen inevitably becomes water during combustion, which
monopolizes energy that could otherwise be used in the combustion process.
The main combustible in natural gas is methane (CH4) but there are also often lesser traces of ethane
(C2H6), propane (C3H8), butane (C4H10) and pentane (C5H12). The greater the hydrogen content in the gases
being burned, the more water produced by combustion. This means that natural gas with higher methane
content and the lower proportions of the other gases will burn more efficiently.

3. Excess Air
Some boiler burners require excess air because their combustion process would be too fuel rich otherwise.
In ultra low-emission burners, excess air is also used to reduce the production of carbon monoxide and
NOx by controlling the temperature of the flame.
Whatever the reasons for the use of excess air, it inevitably absorbs some of the combustion heat, reducing
the efficiency of the heat transfer to the boiler water. This issue can be addressed by calibrating a boiler
regularly, and at multiple firing levels.

4. Ambient Temperature
Ambient temperature is the temperature of the combustion air that enters the boiler basically the
temperature of the air impelled by the forced draft fan. It can have a noticeable effect on industrial boiler
efficiency and boiler efficiency calculations because it affects the net stack temperature, which is the
difference between the ambient temperature and the flue gas temperature.
While it may be tempting to try to reduce ambient temperature to lower flue gas temperature, every 40degree change in ambient temperature can affect industrial boiler efficiency by 1 percent or more. Finding
the right balance is a delicate give-and-take that requires careful evaluation. Most industrial boiler efficiency
calculations assume an ambient temperature of 70 or 80 Fahrenheit.

5. Radiation and Convection Losses

Radiation and convection losses are the heat losses that emanate from a boiler during operation. Theyre
inevitable, so you cant do anything to eliminate them. But you can minimize them.
The two basic strategies for reducing radiation and convection losses are insulation and the control of any
airflow over the surface of a boiler. Properly insulating an industrial boiler will reduce its surface temperature
and lower heat losses. Shielding an industrial boiler from outdoor winds or indoor drafts will prevent heat
from being lost due to air flow over the surface of the boiler.

Conclusion
Once youve determined if your industrial boiler is operating inefficiently, the next step is to try to determine
the underlying causes. While its important to look at the efficiency of your industrial boiler equipment itself,
there are also a number of environmental factors that can affect boiler operation. Addressing them is often
more manageable and less capital intensive that considering new equipment.
If you need help evaluating your industrial boiler system or would like to implement a boiler maintenance
plan to address some of your efficiency concerns, please contact our boiler maintenance and repair division
at 877-360-0858.