EVALUATING BOILER EFFICIENCY

The packaged boiler continues to be one of most cost effective ways to generate steam and hot water.
Selecting the right boiler equipment, however, requires a thorough evaluation according to several criteria:
• Reviewing boiler types

• Comparing features and benefits

• Determining maintenance requirements

• Determining fuel use requirements, also called boiler efficiency

Each year it operates, a typical boiler consumes in fuel many times the initial capital investment. For
example, an industrial boiler purchased for $75,000 can easily consume more than $400,000 in fuel
annually. A one point variation in efficiency is worth $4000 in fuel savings. Boiler efficiency translates into
substantial savings that can pay for a higher efficiency unit many times over.
Often, efficiency staled on a unit covers only a portion of the fuel use picture. Even if the
manufacturer lists efficiency based on input/output calculations, the stated efficiency may
not represent actual operating conditions. Or, the burner arrangement may not be able to
sustain the parameters used to calculate the efficiency over the life of the boiler.
Just What Does Efficiency Mean?
How can efficiency be evaluated in a way that truly reflects fuel consumption? It is
difficult to verify efficiency after the boiler is installed without costly test procedures.
However, techniques are available to prove efficiency before you invest by reviewing the
basic boiler design criteria and data used to calculate the efficiency value.
Efficiency is broken into five segments that allow boiler alternatives to be more
accurately evaluated and compared. Comparing key design features also helps determine
potential boiler efficiency more accurately. Initial cost is the smallest part of an overall
boiler investment. Understanding boiler operating cost is the key to maximizing the
investment year in and year out. The following example compares four alternatives and
their efficiencies.
One boiler has a thermal efficiency of 85%, one has a combustion efficiency of 87%, one
has a boiler efficiency of 80%, and one has a fuel-to-steam efficiency of 83%. Which
boiler will use less fuel in the same application? On the basis of this information, there is
no way to tell. Each type represents something different.
Typically, thermal efficiency reflects how well the boiler vessel transfers heat. The figure
usually excludes radiation and convection losses. Combustion efficiency typically
indicates the ability of the burner to use fuel completely without generating carbon
monoxide or leaving hydrocarbons unburned. However, some combustion efficiency
calculations account for other boiler losses.
Boiler efficiency could mean almost anything. Any fuel-use figure must compare energy
put into the boiler with energy coming out. "Fuel to steam efficiency" is accepted as a
true input/output value.
What Are the Calculation Data?
The first step in cutting through the confusion is to insist on an input/ output (fuel-to-
steam) efficiency. This figure is the only one that represents the boiler's fuel use.
However, even fuel-to-steam efficiency is subject to assumptions in the calculations. In
addition to supplying the efficiency values the boiler vendor should supply the
information used to determine that value. These data include:
• Boiler stack temperature

• Fuel specification

• Excess air levels

• Ambient air temperature and relative humidity

• Radiation and convection losses.

These data have significant impact on the efficiency calculation. They let you quickly validate the stated
efficiency values. A look at each point in detail shows its importance to determining efficiency.
Boiler Stack Temperature
Fuel gas or boiler stack temperature is the temperature of the combustion gases as they
leave the boiler. The temperature represents the major portion of the energy not converted
to usable output. The higher the temperature, the less energy transferred to output and the
lower the boiler efficiency. When stack temperature is evaluated, it is important to
determine if the value is proven. A stack temperature used for a stated efficiency value
should be a proven one, not an estimate.
Is the stack temperature realistic? Compare the stack temperature with the saturated
temperature of the fluid in the boiler and with theoretical values. For example, if a boiler
runs on natural gas with a stack temperature of 350 °F the maximum theoretical
efficiency of the unit is 83.8% For the boiler to operate at a stated 84% efficiency, the
stack temperature must be less than 350 °F. Premium boiler designs can operate near
theoretical efficiency values. However, no boiler operates above these values. Boilers not
designed with maximum heat transfer design and high-quality burner arrangements
operate significantly below these values.
Fuel Specification
The fuel specified has a dramatic effect on efficiency. With gaseous fuels, the higher the
hydrogen content, the more water vapor is formed during combustion. The result is
energy loss as the vapor absorbs energy in the boiler and lowers the efficiency of the
equipment.
The specification used to calculate efficiency must be based on the fuel to be used at the
installation. As a rule, typical natural gas has a hydrogen/-carbon (H/C) ratio of 0.31. If
an H/C ratio of 0.25 is used for calculating efficiency, the value increases from 82.5% to
83.8%. However, if this higher efficiency fuel is not available, the boiler will never
operate at the higher efficiency level.
Excess Air Levels
Excess air is supplied to the boiler beyond what is required for complete combustion. A
certain amount of excess air is provided to the burner as a safety factor for sufficient
combustion air.
Excess air, however, uses energy. Heat is absorbed by the air instead of being transferred
to output, and efficiency falls. A quality burner with simple, repeatable linkage and a
high-quality fan and damper arrangement can operate at 15% excess air at the
installation. Many burners operate at 15% or less under controlled conditions, but fall
short in the field. If the efficiency calculation uses 15% excess air, find out if the boiler
actually operates at this level. If less that 15% is used, the value should be challenged. No
efficiency benefit occurs during operation unless a reliable oxygen trim system is
provided and the burner is of very high quality.
Ambient Air temperature and Relative Humidity
Ambient conditions have a dramatic effect on boiler efficiency. Most efficiency
calculations use an ambient temperature of 80 °F and a relative humidity of 30%.
Efficiency changes more than 0.5% for every 20 °F change in ambient temperature.
Radiation and Convection Losses
Boilers are insulated to minimize heat losses from the vessel. However, every unit
experiences some losses. These losses are determined by the boiler skin temperature,
amount of surface area, and ambient conditions. If a boiler has a high skin temperature
(rear of a wetback firetube boiler, for example) and the radiation and convection losses
do not reflect this condition, the value should be challenged.
What Other Factors Are Involved?
These five factors form the basis for comparing boiler fuel use. Comparing them with the
stated efficiency value lets you understand efficiency values more thoroughly and
compare them more effectively. The comparison, however, is useful only if combined
with a comparison of boiler design. For example, if two boilers are stated as operating at
the same stack temperature and one has less heating surface, stack temperature on the
boiler with less heating surface should be challenged.
If two boilers are stated as operating at 15% excess air and one has a very complex
burner linkage design or does not include a high-quality air damper arrangement, it is
questionable that it will operate at the stated excess air level. If two boilers of similar
length and width are compared and one has more flue gas passes (number of times the
flue gas travels through the boiler heat exchanger), the boiler with the greater number of
passes should have a lower stack temperature.
Efficiency is a complex issue. Many factors influence boiler efficiency and stated values
can be interpreted in various ways by vendors. The bottom line is to examine the five
factors used in the efficiency calculation, then work with vendors who can point to
projects where the stated efficiencies and stack temperatures are realized. Once a boiler is
purchased, it is difficult to reverse the decision. Performing basic research before you buy
provides the highest efficiency boiler and the maximum return on your investment.
Verifying Efficiency
Verifying efficiency comes down to answering four questions.
 • Does the efficiency value represent input/output?

• Do the five efficiency factors reflect realistic conditions at the installation?

• Can the product design support the efficiency value?

• Are existing units operating at the stated efficiency?

Knowing the answers to these questions helps provide an accurate comparison for a boiler evaluation and
ensure minimum boiler operating costs for the life of the equipment.