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Energy efficiency for industrial boilers is a highly boiler specific characteristic. No two boilers are alike. There are two identically designed, constructed side by side, stoker fired boilers in Indiana burning the same fuel that have very different performance characteristics. Like twin teenagers, they are not the same.

Consideration of energy efficiency for industrial boilers, more often than not, is simplified and categorized to a one-size-fits-all approach. Just as when considering teenagers, this does not work. While everyone would like to believe their teenager is gifted and talented and in the 80th percentile of the population, we know that is not necessarily the case.

We also know, as for boilers, the average teenager is not representative of a widely diversified population. If you think it is, ask any parent with teenagers or an industrial boiler operator. While the variables associated with energy efficiency are more limited than those associated with a teenager, they are in no way any less complicated.

Four factors are critical for assessing energy efficiency in the industrial powerhouse supplying energy to make products for the benefit of customers in a highly competitive international market place. These are:

1. fuel type,
2. combustion system limitations,
3. equipment design, and
4. steam system operation requirements.

Furthermore, the industrial facility’s complexity, location, and objective complicate them. It is important for the industrial company to remember, unlike the utility, energy is a smaller portion of the final product price. However, without energy there is no final product or service. Needless to say, without products or services there is no need for people to do the work.

This white paper will address the efficiency-related aspects of the four primary factors affecting the industrial boiler and the factors affecting application of combined heat and power systems to industrial facilities. A copy of the Background Paper on the Differences Between Industrial and Utility Boilers is included as an appendix to help understand the diversity of the industrial boiler population. From the EPA Boiler MACT Database, there are about 22,000 Industrial-Commercial and Institutional boilers greater than ten million BTU’s per hour heat input.

Content:
NEW vs. EXISTING UNITS
ANNUAL AVERAGE vs. MCR DESIGN
FUEL TYPE
COMBUSTION SYSTEMS
EQUIPMENT DESIGN
SYSTEM OPERATIONS
COMBINED HEAT AND POWER
COMBINED HEAT and POWER EFFICIENCY
APPLICATION OF COMBINED HEAT AND POWER SYSTEMS
SUMMARY AND CONCLUSIONS

Download ENERGY EFFICIENCY & INDUSTRIAL BOILER EFFICIENCY An Industry Perspective(13 pages pdf files, 330 Kb)