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Energy Efficiency Improvement Strategies for Industrial

Boilers: A Case Study
Rahul Dev Gupta, Sudhir Ghai1, Ajai Jain2
Department of Mechanical Engineering, M.M. Engineering College, Mullana, (Ambala), 1Centre of Energy Studies, Indian Institute of
Technology, Delhi, 2Department of Mechanical Engineering, National Institute of Technology, Kurukshetra, India

ABSTRACT Access this article online

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In this paper, the findings of boiler house efficiency improvement study carried out in a large boiler house
DOI:
unit of a pulp and paper mill has been presented. The causes of poor boiler efficiency were various heat 10.4103/0976-8580.74541
losses such as loss due to unburnt carbon in refuse, loss due to dry flue gas, loss due to moisture in
Quick Response Code:
fuel, loss due to radiation, loss due to blow down, and loss due to burning hydrogen, etc. The various
heat losses were analyzed and a set of recommendations were made to the plant management for
implementation, so that efficiency of boiler can be increased. Five important recommendations were
implemented by plant management, and it has been seen that there is tremendous increase in boiler
efficiency. Economic analysis reveals that the expenditure on the proposed system will be recovered in a
short span of time. This work, with only five recommendations implemented, has resulted in net increase
of 2% in overall boiler efficiency and an annual saving of Rs. 34,12,395. In addition, it is observed that
carefulness in the operation of boiler can help a great deal in energy efficiency improvement in boiler.

Key words: Energy conservation, Boiler efficiency, Boiler heat losses

1. INTRODUCTION and modification of the boiler.

Energy is an indispensable instrument in the progress
of human race. Today’s high standard living has been
possible only through the judicious use of various energy
resources at command. Realizing the fact that energy
is the sinew of economic growth, energy management
and energy conservation are of paramount importance.
The above along with energy efficiency improvement
are the only cost-effective and viable means of ensuring
the proper use of finite natural resources, minimizing
operating expenses, and increasing the profitability of
enterprises.
The considerable rise in plants utilizing process heat
(pulp and paper, sugar mills, refineries, petrochemical,
etc.) and electricity throughout the world have resulted
in enormous increase in capacity and number of process
heat boiler house units and thermal power plants
installations. Such expansions coupled with escalating
cost of fuel, have imposed an urgency to ensure that
the boilers are operated as near to optimum conditions
as possible. There is a need felt to carry out energy
audit and efficiency test to analyze the various heat
losses, with an aim to identify the major heat losses
and causes of poor boiler efficiency. Efforts can then
be made to minimize heat losses by proper operation
Zeitz [1] has described upon the various heat loses in
boilers, and these are heat losses due to unburnt carbon
in refuse, heat loss due to dry flue gas, heat loss due
to moisture in fuel, heat loss due to moisture from
burning hydrogen, heat loss due to formation of carbon
monoxide, heat loss due to sensible heat in bottom ash,
heat loss due to radiation and convection, heat loss due
to blow down. Energy Research Institute [2] provided
information on the strategies for minimizing the heat
losses. The biggest energy loss in a conventional fossil
fuel fired boiler goes “up the chimney” that is, out the
stack. The loss could amount to as much as 30%−35%
of the fuel input in worst cases. Changnani [3] has
discussed about combustion and effect of excess air in
his research paper. Excess air increases the heat loss
because air enters at ambient temperature and leaves
the boiler at high temperature, taking a considerable
amount of useful heat with it. Beer [4] has proposed
a number of simple measures that could increase the
energy efficiency of boiler. “Multi layer coal sorting”
can sort coal particles in layers by size, with most of
the larger particles on bottom of coal bed, medium
size particles in the middle and smaller on top. The
resulting multilayer structure leads to the reduction of
unburned carbon in the slag even with a reduced excess

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Gupta, et al.: Energy efficiency improvement strategies for industrial boilers

air supply to the grate. As a result, boiler efficiency can
be improved by 5%−6%. Ozdemir [5] has discussed that
operation of boilers at optimum combustion efficiency
involves control of excess air supply. Ideally, excess air
and stack temperature should always be maintained at
the optimum levels established through the tune up
procedures.
This research work is focused on the improvements
in boiler efficiency resulting from reduction in
various heat losses [6]. The aim of this paper is not to
present something new, but rather, to raise awareness
and to show the tremendous energy and cost saving
opportunities missed as a result of observing some
simple and obvious conservation measures.
2. DETAILS OF THE CASE STUDY
The efficiency test and energy conservation study has
been conducted in the boiler house of a leading Pulp
& Paper Mill. After calculation, the sum of various
heat losses and boiler efficiency comes to be 19.015%
and 80.98%, respectively [Table 1]. On the basis of
efficiency test conducted and further analysis of
various heat losses, the following recommendations
were proposed for energy efficiency improvement and
energy conservation.
2.1 Coal Preparation and Handling
Sieve analysis of coal was carried out and the average
value of Sieve analysis [7] comes to be 13.5%, which is
on higher size and shows oversize coal. Because of this
oversize coal, unburnt loss in bottom ash is quite high.
To control this loss, Sieve analysis has to be carried out
on a fixed time-frame basis (once in every shift) on coal
coming out of the crusher. It is better to install one sieve
analyzer in boiler house, so that sieve analysis can be
Table 1: Results of Efficiency Test
Loss due to kJ/ kg Percentage
Coal
Dry flue gas 1328.53
Moisture in fuel 256.03
Moisture from burning hydrogen 843.47
Combustibles in refuse 1347.03
Formation of CO 17.62
Moisture in combustion air 56.65
Sensible heat in bottom ash 92.11
Radiation and convection − 0.7
Blow down − 0.7
Total losses 19.015%
Efficiency = 100 − total losses = 80.98%
carried out there itself and feedback can be sent to coal
crusher people.
2.2 Excess Air
Boiler had been running at 75% excess air level and
8.8% oxygen in flue gas. This is on very high side.
Operate boiler at lower excess air (around 40%-50%).
Online oxygen analyzer [8] or oxygen trim system
needs to be installed for proper control on excess air
and oxygen content in flue gas. In the absence of online
oxygen analyzer, it is recommended to conduct flue gas
analysis after every 2 hour and adjust the combustion
excess air, as condition changes.
Under grate air must be properly distributed for peak
burning efficiency. It is important to ensure periodic
surveillance and maintenance to replace worn or broken
grate sections. Air infiltration to the furnace must be
minimized. It takes place through furnace wall seam
areas or through the stoker. Sealing the furnace at
potential leak sites reduces air infiltration.
2.3 Soot Blower Operation
Installed soot blowers are not functioning since long
because of soot blowers master steam control valve
problem. It is recommended that the soot blower
steam control valve needs immediate repair and in this
regard valve supplier may be contacted and overhaul
the valve, if needed. It is recommended to carry out
the soot blower operation once in every shift. Soot
blowing should also be carried out in economizer and
air preheater.
2.4 Blow Down
It is observed that blow down from boiler is on
continuous basis (CBD). Usually, the blow down
is excessive, just to be sure. Automatic blow down
system [9] can be installed, consist of continuous
monitoring of conductivity, and an automatic blow
down sequence at a preset level. This automatic system
can save energy wasted by continuous system.
loss 2.5 Insulation
5.93 It is observed that some boiler surfaces and valves are
1.14 not properly insulated. One rule of thumb is that any
3.77 surface above 120 ºF should be insulated, including
6.03
boiler surfaces, steam or condesate piping, valves and
0.0785
0.255 fittings. All the damaged or worn out insulation should
0.41 be changed on priority basis. Boiler casing should be
checked for hot spots. Hot spots are an indication of
excessive heat losses from the boiler enclosure. The
temperature of surface of outer skin should not be more
than 50 ºC.

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Gupta, et al.: Energy efficiency improvement strategies for industrial boilers
2.6 Periodic Training Program
It is suggested that awareness on energy efficiency
aspects be created among all employees; and especially
boiler operators need training in energy conservation
area [10]. It shall enhance overall efficiency of boiler
house. Trained personnel shall also keep records,
documents systematically and professionally.
2.7 On Going Sampling and Monitoring Schedule
For proper control of unburnt in bottom ash and fly
ash, it is suggested that in a shift of 8 hour, at least four
samples of bottom ash & fly ash should be taken, and
they may be sent for testing in lab for un burnt carbon
[11]. This will help in reducing the unburnt carbon loss.
3. IMPLEMENTATION OF VARIOUS
RECOMMENDATION MADE FOR
IMPROVED ENERGY EFFICIENCY
OF BOILER
i. On the basis of recommendation made, the plant
management instructed the boiler operators to send
the coal sample for sieve analysis, once in every
shift. [Earlier they used to do it, twice in a week].
Because of this, now there is proper control on coal
size and any deviation in coal size can be checked
timely.
ii. Because of regular and more frequent coal sieve
analysis, the average reading of sieve analysis
reduced from 13% to 7.5%. Because of this, the
heat loss due to unburnt in front ash reduced from
3.48% to 3.08% and boiler efficiency also improved
by 0.40%.
iii. On the basis of recommendation made, the plant
management instructed the boiler operators to
carry out the flue gas analysis, in every 2 hour.
Now boiler operators adjust the combustion excess
air, on the basis of flue gas analysis. Because of
this, now the boiler is running on low excess air
and heat loss due to dry flue gas has reduced from
5.93% to 4.97% [Figure 1]. And boiler efficiency
has improved by 0.96%.
iv. It was recommended to repair the installed soot
blowers. They have started the process of repairing
of installed soot blower.
v. On the basis of recommendation made, the boiler
operators have started varying the amount of blow
down as per quality of water, e.g., total dissolved
solids (TDS) in water [12]. Although the blow
down is still on continuous basis, but its quantity
has reduced, and by doing this, the heat loss due
to blow down, has been reduced.
54 Journal of Engineering and Technology | Jan-Jun 2011 | Vol 1 | Issue 1
7
6
%age Heat Loss
5
4
3
2
1
0
Dry flue Moisture Moisture Combustibles Formation Moisture in Sensible
gas in fuel from in refuse of CO combustion heat in
burning air Bottom Ash
hydrogen
Before implementing Energy Conservation Techniques
After implementing Energy Conservation Techniques
Figure 1: Comparison of heat losses
vi On the basis of recommendation made, all the
cracks in the furnace insulating materials have
been repaired. All the damaged or worn out
insulation has also been changed. This has resulted
in reduction of heat loss due to radiation and
convection [13].
viii. On the basis of recommendation made, the boiler
operators started taking samples of bottom ash and
fly resulted in proper control on heat loss due to
unburnt in bottom and fly ash [14]. Because of this
and other measures, the heat loss due to unburnt
in refuse reduced from 5.98% to 5.08% and boiler
efficiency has increased by 0.9%.
4. RESULT
During the efficiency test, the efficiency of boiler comes
out to be 80.98%. To improve the boiler efficiency,
various losses were identified. Their relative magnitude
was calculated and then various recommendations
were made to the plant management for improving
the boiler efficiency. After implementing some of the
recommendations made, efficiency test was again
conducted. The efficiency of boiler has increased from
80.98% to 82.98% [Table 2].
i. By controlling excess air (air-flow rate), boiler
efficiency improved from 80.98% to 81.94%.
ii. By sifting and segregating coal fines, carbon content
in front and fly ash was reduced from 13% to 12.1%
and 30% to 26.34%, respectively. This meant saving
in coal consumption of 444.6 tons per annum.
iii. By employing better insulation on steam pipes,
and by employing other recommendations, there
was further improvement in boiler efficiency and
boiler house efficacy.
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Gupta, et al.: Energy efficiency improvement strategies for industrial boilers

Table 2: Efficiency Test of Boiler after Implementing
the Recommendations
Loss due to (kJ/kg) Percentage
Coal
Dry flue gas 1113.74
Moisture in fuel 252.4
Moisture from burning hydrogen 846.50
Combustibles in refuse 1139.39
Formation of CO 17.23
Moisture in combustion air 46.93
Sensible heat in bottom ash 88.40
Radiation and convection − 0.7
Blow down − 0.7
Total losses
Efficiency = 100 − total losses= 82.98%
iv. Total monetary gains of Rs. 34 12 395 per annum
could be achieved which comprised of Rs. 16 56
332 savings due to reduction of excess air supply to
boiler furnace from 68.9% to 40.04%, Rs 15 56 115
savings from separating coal fines and controlling
coal size prior to the process of conveying of coal
to the boiler furnace. And Rs. 1 99 948 savings on
account of all other recommendations that were
implemented.
5. CONCLUSION
This work determines and concludes that, tremendous
positive gains can be attained by employing above
approach in a given energy intensive activity, in this
case in boiler house of a large paper mill. Overall
boiler efficiency on account of all improvement
recommendations has increased by 2% from 80.98% to
82.98%, which is a remarkable increase given the facts
that no new equipment has replaced old boiler house
equipment. This increase in efficiency speaks volumes
about use of energy management which is need of hour.
The monetary benefits thus accrued, can be gainfully
used elsewhere, which shall help in providing vitality
to the industry.
There is a great scope of application of energy efficiency
improvement techniques in boilers (particularly coal
fired). It is hoped that energy efficiency improvement
techniques, as embedded in this work, would go a long
loss
way in improving efficiency of boilers. If immediate
4.97
steps are taken to create energy efficiency consciousness
1.12
3.77 in industries and a national policy program on energy
5.08 conservation is implemented, it is hoped that the
0.0769 major problems associated with energy and fuel can be
0.209 brought under control. This will lead to an economy
0.394 with higher productivity and sustained growth.
17.02% REFERENCES
1. R. A. Zeitz, Energy Efficiency Handbook, Council of Industrial Boiler
Owners (CIBO- Burke VA), pp. 25-65, 2003.
2. R. Virendra, Energy Conservation Potential in Coal Handling Plants
of Thermal Power Stations, J Ener Mgmt, pp.11-22, July-Sept 1997.
3. D. Chnangani, Monitoring & Controlling the Stack Gas Temp,
Available from: http://www.energymanagertraining.com, [last
cited in 2004].
4. J. M. Beer, A Proposed Industrial Boiler Efficiency Improvement In
Shanxi, Potential Carbon DioOxide Mitigation- Health Benefits
And Associated Costs, J of Appl Ener, vol. 71, pp. 275-285, 2002.
5. E. Ozdemir, Energy Conservation Opportunities with a Variable
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pp. 981-993, 2004.
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9. P. Kumar, and A. K. Tyagi, Managing Energy Efficiency in Hotels and
Commercial Buildings (TERI- New Delhi) 2002.
10. P. Bowonder, Energy Audit in Manufacturing Industries, Energy
conservation and Management (Administrative Staff College of
India, Hyderabad) 1996.
11. P. W. Callaghan, Energy Management (McGraw Hill Book Company
Limited, Berkshire, England) 1996.
12. P. Dockrill, Boilers & Heaters-Improving Energy Efficiency (Federal
Industrial Boiler Program, Canada) 2001.
13. G. Hain, Boiler Efficiency And Steam Quality- The Challenge Of
Creating Quality Steam Using Existing Boiler Efficiencies (The
National Board of Boiler & Pressure Vessel Inspectors, USA) 2004.
14. D. Jaber, and G. A. McCoy, Steam System Management – Best
Practises (Alliance to Save Energy, Washington State University,
USA) 2001.

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Gupta, et al.: Energy efficiency improvement strategies for industrial boilers

Authors Biography
Rahul Dev Gupta is presently serving as a faculty member in Mechanical Engineering Department of M.M. Engineering
College, Mullana. His areas of interest include industrial engineering, cellular manufacturing systems & energy
management. He is a Life Member of the Indian Society of Technical Education (ISTE) and an Associate Member of
Institution of Engineers. He has 17 publications in international and Indian journals and conferences.
E-mail: rdg_76@yahoo.com

Dr. Sudhir Ghai has done his Ph. D from Centre of Energy Studies of IIT Delhi. He has about 18 years of teaching
experience. His areas of interest include energy conservation & management and alternate fuels for IC engines. He
has more than 20 publications in international and Indian journals and conferences.
E-mail: sudhir_9_98@yahoo.com

Dr. Ajai Jain is presently serving as a faculty member in the Mechanical Engineering Department of National Institute of
Technology, Kurukshetra, India. He has about 17 years of teaching experience. His areas of interest include computer
aided design, flexible and automated manufacturing systems. He has more than 30 publications in international and
Indian journals and conferences to his credit.
E-mail: ajaijainfme@nitkkr.ac.in

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