Energy losses add up over time and can cost you and your facility a lot of money. It’s important to identify the issues that are causing your energy bills to skyrocket, and we’re here to explain them. Here are some of the basic reasons for boiler energy loss and some ways to decrease discharge during operation.

Boiler Short Cycling

A boiler may short cycle by shutting down after it produces enough heat. Over time, this type of process can be inefficient. The boiler cycle includes a firing interval, a post-purge, an idling time, and a pre-purge. Then, firing starts again. Efficiency also decreases when multiple boilers are running at low firing rates.’

Changing your automatic cycling settings can assist in boosting productivity, and many units can be set to run in line with peak demand times. Schedule loads to help optimize performance by bringing the boiler online as loads increase, and then taking less-efficient boilers offline.’

Heat Loss in Flue Gases

Heat loss in the flue gases can be a huge culprit for high energy costs, but proper maintenance can help you avoid this issue.’Flue gas heat loss is due to the temperature of the gas leaving the furnace. The hotter the gas is in the stack, the less efficiently the boiler can perform.

The gas temperature can become too high if the burner generates more heat than is necessary for the load. That in turn, can damage parts of the machine. Gas can also overheat if heat transfer surfaces aren’t working correctly. Most likely in this case, heat-transferring surfaces will need to be cleaned.

Flue gases shouldn’t become too cool, though’if they fall below the dew point, it could cause corrosion in the boiler. Arrange for a professional to check the flue gas outlet on a regular basis in order to avoid flue gas energy loss.’

Radiation Loss

Radiation loss is another component that can cause high energy costs. Radiation loss occurs because the boiler is hotter than its environment, resulting in heat being transferred to the surroundings. This explains why sometimes, the area around a boiler can be warmer than the ambient air. Without the right insulation properly installed, radiation losses can be sizable.

Normally, a water tube boiler at or above 5MW will lose between 0.3% and 0.5% to its surroundings. That loss can remain constant’so the boiler can lose energy even when it’s not producing steam and is on standby.

Steam Emission

While the boiler will emit heat from its surface, it can also lose energy when steam or hot water escapes. These losses are a result of pipework. Leaks or improperly working steam traps are often the culprits of steam loss. Check regularly that the hot water and steam outlet is properly working in peak condition to avoid steam loss. Pipes in good condition will function at their best to properly direct water and steam.

American Boiler Company can assist your facility in ensuring that all commercial boiler equipment is running in peak condition. Let us help make your facility more energy-efficient so you can enjoy cost-savings for years to come.