Utilities
Boiler Efficiency Calculator
Calculate thermal efficiency of steam boilers in dairy plants using steam output, fuel consumption, and calorific value.
Formula
(steamOutput * (enthalpySteam - enthalpyFeedwater)) / (fuelConsumption * calorificValue) * 100
steamOutput
Steam Generated (kg/hr)
enthalpySteam
Enthalpy of Steam (kcal/kg)
enthalpyFeedwater
Enthalpy of Feed Water (kcal/kg)
fuelConsumption
Fuel Consumption (kg/hr)
calorificValue
Gross Calorific Value of Fuel (kcal/kg)
Worked Example
1
Given:
calorificValue = 8000
enthalpyFeedwater = 60
enthalpySteam = 660
fuelConsumption = 160
steamOutput = 2000
2
Apply the formula:
(steamOutput * (enthalpySteam - enthalpyFeedwater)) / (fuelConsumption * calorificValue) * 100
3
Result:75 %
What is Boiler Efficiency?
Boiler efficiency is the ratio of useful heat output (in the form of steam) to the total heat input from fuel. It indicates how effectively the boiler converts fuel energy into steam energy.
Boiler Efficiency (%) = [Steam Output × (H_steam − H_feedwater)] ÷ [Fuel × Calorific Value] × 100
Typical Boiler Efficiencies
| Boiler Type | Efficiency |
|---|---|
| Water tube boiler | 80–88% |
| Fire tube boiler | 75–85% |
| Fluidized bed | 80–90% |
| Biomass boiler | 70–78% |
Common Fuels in Dairy Plants
| Fuel | Calorific Value (kcal/kg) |
|---|---|
| Rice husk | 2800–3200 |
| Groundnut shell | 3500–4000 |
| Bagasse | 2300–2500 |
| Coal | 5000–6000 |
| Furnace oil | 9700–10000 |
| LDO/Diesel | 10000–10500 |
| LPG | 11900 |
| Natural gas | ~8500 kcal/m³ |
How to Improve Boiler Efficiency
- Reduce excess air: Control combustion air for complete burning
- Recover waste heat: Install economizer and air preheater
- Maintain steam traps: Replace faulty traps immediately
- Insulate steam lines: Reduce radiation losses
- Treat feed water: Prevent scaling and corrosion
- Regular blowdown: Remove dissolved solids from boiler drum