1. Analyse
Boiler-efficiency data and the factory gas KPI were analysed across the four boilers.
Improving boiler sequencing efficiency
When meeting steam demand with the wrong boiler mix increases fuel use
Customer scenario
A manufacturing site operated four boilers to provide the steam required by production. Boiler-efficiency calculations in Strata showed that Boilers 1, 2 and 3 were significantly more efficient than the larger 800 HP Boiler 4. By changing the operating sequence, the site could meet demand with the more efficient boilers and reduce gas consumption.
What our energy experts revealed
Boiler efficiency varied across the boilerhouse
Efficiency calculations showed that Boilers 1, 2 and 3 materially outperformed the larger Boiler 4.
Existing assets offered a lower-energy operating strategy
The opportunity was to increase utilisation of Boilers 1, 2 and 3 and take Boiler 4 offline during normal operation.
Normal sequencing was increasing fuel use
The less-efficient 800 HP boiler was being used when the smaller, more-efficient boilers could meet demand.
From insight to action
2. Interpret
Engineering analysis identified the efficiency gap between Boilers 1, 2 and 3 and Boiler 4.
3. Improve
The boiler sequence was changed to prioritise the more-efficient units during normal operation.
4. Acheive
The boiler sequence was changed to prioritise the more-efficient units during normal operation.
Why boiler sequencing matters
Boilers of different sizes and configurations do not necessarily operate at the same efficiency. When a less-efficient boiler is used ahead of more-efficient available units, the boiler house can consume more gas than necessary while still meeting steam demand. Comparing boiler efficiency and sequencing operation around the most efficient available assets can reduce fuel use without changing the production requirement.
Could your boiler sequence be increasing fuel consumption?
Talk to our energy experts to learn how operational data and boiler-efficiency analysis can identify a more efficient operating strategy.
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