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  • Writer's pictureAnubhav Gupta

Reduce your Energy Bill - Boiler Aspect: 2023

Updated: Mar 1

How Automation helps you save on energy costs in boiler installations?

A boiler is equipment used to produce steam for various applications. The primary change happening during steam production is the conversion of energy stored in fuels (in form of chemical energy) to heat energy, and then that heat energy is stored in water which causes water to heat enriching its enthalpy in the liquid state, thereafter in form of Latent heat of evaporation/condensation while a change of phase from liquid to gas and thereafter in form of enthalpy of superheat (If the process needs superheated steam). At every stage, there is the involvement of heat transfer and thus there is heat loss.

The efficiency needs to be calculated and there are two methods:

Boiler efficiency direct method

Simple calculation of ratio of amount of heat present in output steam to the energy input given as per calorific value of fuel in totality.

Boiler efficiency Indirect method:

Utilizable energy is calculated by calculating total heat energy available in fuel and then subtracting each of the below losses after individual calculations. 1. Loss due to Dry flue gas 2. Loss due to hydrogen in fuel 3. Loss due to moisture in fuel 4. Loss due to moisture in air 5. Loss due to carbon mono-oxide 6. Loss due to surface radiation, convection, leakages etc 7. Loss due to unburnt fuel in fly ash 8. Loss due to unburnt in bottom ash 9. Blow Down Losses 10. Soot Blower Energy consumption 11. Auxiliary Energy Consumption.

Measurements required for indirect loss calculation:
a) Flue gas analysis

1. Percentage of CO2 and O2 in flue gas 2. Percentage of CO in flue gas 3. Temperature of flue gas

b) Flow Analysis

1. Fuel 2. Water 3. Steam 4. Condensate 5. Combustion Air 6. Blow Down

c) Temperature profile

1. Flue Gas 2. Steam 3. Makeup Water 4. Condensate return 5. Combustion Air 6. Fuel 7. Boiler Feed Water

d) Pressure Measurements

1. Steam 2. Fuel (in case of gaseous or liquid fuel) 3. Combustion air (both primary and secondary) 4. Draft

e) Water Parameters

1. Total Dissolved Solids 2. pH 3. Blow Down rate & quality

Typical Instrument list used by us:

1. Flue gas analyzer – fixed type in stack 2. Temperature indicators – from fuel to flue gas 3. Draft gauge 4. TDS Meter 5. Flow Meters – both liquid and gas

Optimization of each and every loss is the key to best boiler performance. We at Vrinda Automations Pvt. Ltd. refer to your process performance and monitor the progress continuously, to ensure that the best results are delivered. For any queries please visit us at or drop an email to

#energysaving #boiler #boilerautomation #powergeneration #processautomation #steamboiler

Published by Vrinda Automations Pvt. Ltd. There is a need to save energy not only for environmental concerns but also to reduce energy bills and increase business competency. Do get in touch if boiler automation is what you seek. #business #energy #automation #environmental #boiler #processautomation #energysaving #deltaelectronics #corrugatedbox #corrugation #paper #sugarindustry #sugar #textileindustry #textiles #powerplant

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