Boiler Operational Efficiency Best Practices from US DOE

Full technical report

In the report “Wise Rules for Industrial Energy Efficiency”, the EPA develops a comprehensive list of baic rules relating to boiler efficiency improvements.

• Boiler Rule 1. Effective boiler load management techniques, such as operating on high fire settings or installing smaller boilers, can save over 7% of a typical facility’s total energy use with an average simple payback of less than 2 years.

• Boiler Rule 2. Load management measures, including optimal matching of boiler size and boiler load, can save as much as 50% of a boiler’s fuel use.

• Boiler Rule 3. An upgraded boiler maintenance program including optimizing air-to-fuel ratio, burner maintenance, and tube cleaning, can save about 2% of a facility’s total energy use with an average simply payback of 5 months.

• Boiler Rule 4. A comprehensive tune-up with precision testing equipment to detect and correct excess air losses, smoking, unburned fuel losses, sooting, and high stack temperatures can result in boiler fuel savings of 2% to 20%.

• Boiler Rule 5. A 3% decrease in flue gas O2 typically produces boiler fuel savings of 2%.

• Boiler Rule 6. Every 40°F reduction in net stack temperature (outlet temperature minus inlet combustion air temperature is estimated to save 1% to 2% of a boiler’s fuel use.

• Boiler Rule 7. Removing a 1/32 inch deposit on boiler heat transfer surfaces can decrease a boiler’s fuel use by 2%; removal of a 1/8 inch deposit can decrease boiler fuel use by over 8%.

• Boiler Rule 8. For every 11°F that the entering feedwater temperature is increased, the boiler’s fuel use is reduced by 1%.

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