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Fuel Efficiency in Boilers

 


HOW SCALE AFFECTS HEAT TRANSFER

It is important to understand how even the smallest amount of scale fouling can affect the heat transfer efficiency of the boiler. When heat transfer is at its peak, only minimal amounts of fuel are necessary to provide the amount of steam your production demands. Increased scale impedes heat transfer, requiring more fuel to create the necessary steam for heat or production. The following chart illustrates the amount of fuel needed as your heat transfer decreases due to scale fouling. That decrease directly impacts your profit picture.

BOILER SCALE INSULATING PROPERTIES

Scale Thickness
in Inches

Avg Efficiency
Loss

Oil Wasted Per
1000 Gallons

Coal Wasted
Per Ton

Gas Wasted Per
1000 Cubic Feet

1/64

4% 40 80 lbs. 40
1/32 7% 70 140 lbs. 70
1/16 11% 110 220 lbs. 110
1/8 18% 180 360 lbs. 180
3/16 27% 270 540 lbs. 270
1/4 38% 380 760 lbs. 380
3/8 48% 480 960 lbs. 480
1/2 60% 600 1200 lbs. 600
5/8 74% 740 1480 lbs. 740
3/4 90% 900 1800 lbs. 900

The chemical/mineral composition of different waters makes the boiler scale insulating properties vary. This fact makes it difficult to quote the exact heat insulation value of any scale thickness. Efficiency loss can be as high as 15% for each 1/16th inch of normal calcium-magnesium scale and over twice as high with iron-silica scale. The above table is an average of the heat loss by scales of various types.

To see the remarkable consistency of Bon Aqua™ treatment, click here.

Click here for some interesting and informative boiler water treatment data.

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