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Fuel Savings and Efficiency Calculator

The document is a fuel savings estimator tool from MicroMod that allows users to calculate potential fuel and cost savings from efficiency improvements to steam boilers. It includes calculators to estimate annual fuel usage and costs under current and improved efficiency scenarios. It also includes a boiler efficiency analysis tool that determines the current and potential improved efficiencies based on operating data. The tool indicates that a 4% efficiency gain could be expected from properly adjusting air flow, with estimated annual savings provided for different boiler and fuel types.

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rajayu20002724
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337 views6 pages

Fuel Savings and Efficiency Calculator

The document is a fuel savings estimator tool from MicroMod that allows users to calculate potential fuel and cost savings from efficiency improvements to steam boilers. It includes calculators to estimate annual fuel usage and costs under current and improved efficiency scenarios. It also includes a boiler efficiency analysis tool that determines the current and potential improved efficiencies based on operating data. The tool indicates that a 4% efficiency gain could be expected from properly adjusting air flow, with estimated annual savings provided for different boiler and fuel types.

Uploaded by

rajayu20002724
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLS, PDF, TXT or read online on Scribd
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MicroMod Fuel Savings Estimator

For heating steam boilers from 50 to 600 BHp or 10,000 to 70,000 Steam Lbs/Hr
Make entries in yellow boxes to calculate fuel usage and potential savings
Calculation for Boiler No.:
Units:

Boiler Maximum Load


Annual Fuel Requirement
Potential savings goal

Cost/unit of energy
Cost/MM BTU
Annual fuel cost/boiler
Savings

200 BHp
27,518 MM Btu/Yr

Based on load profile as shown in graph below

4.0% expected increase in efficiency, per boiler


Use the Boiler Efficiency Calculator to estimate efficiency gain!
Electricity Natural Gas Heating Oil
kwh
decatherm
gallon
$0.10
$10.00
$1.85
$29.30
$10.00
$13.70
$806,282
$275,184
$377,104
$32,251
$11,007
$15,084

Coal
ton
$54.00
$2.25
$61,916
$2,477 per boiler, per year

Heating M onth vs Pct Load


120%
100%
80%
60%
40%
20%
0%

% Load

MicroMod Fuel Savings Estimator


For process steam boilers from 50 to 600 BHp or 10,000 to 70,000 Steam Lbs/Hr
Calculation for Boiler No.:
Steam Type

Saturated
Units:

Boiler Maximum Load


Efficiency

100 Bhp
80.0%

Average Load

80.0%

Hrs/day in use
Days/Yr in use

16
200

Annual Fuel Requirement


Potential savings goal

Cost/unit of energy
Cost/MM BTU
Annual fuel cost/boiler
Savings

10,720 MM Btu/Yr
4.0% expected increase in efficiency, per boiler
Use our Boiler Efficiency Calculator to estimate efficiency gain!
Electricity Natural Gas
kwh
decatherm
$0.10
$10.00
$29.30
$10.00
$314,093
$107,200
$12,564
$4,288

No. 2 Oil
gallon
$1.85
$13.70
$146,904
$5,876

No. 6 Oil
gallon
$1.10
$7.33
$78,613
$3,145

Coal
ton
$54.00
$2.25
$24,120
$965 per boiler, per year

MicroMod Boiler Efficiency & Payback Analysis (S. G. Dukalow Empirical Method)
Enter Data in shaded boxes only. All other values are calculated.

Accuracy: Within Tolerance of Fuel Analysis & Data


Assumptions:
(1) Standard Fuel Analysis
(2) Boiler Properly Maintained

Boiler Data:
Boiler Rating
Average Load
Fuel Type:
Coal % H2O

75
60
No. 6 Oil
5

Units:
1000 lbs/hr
1000 lbs/hr

Percent Load
80.0%

If coal or solid is selected as fuel type, enter % moisture as fired.

Latent Loss =

5.0%

RadiationLoss =

0.8%

From ABMA Chart. Note: Assumes 4 Water Cooled Walls in Furnace.


1000 Btu/Lb Steam Heat Gained

UnAcct Loss =

1.0%

Manufacturer's Margin

Efficiency Check:
Base Case (as Found):

New Case:

Have the plant operator set the boiler load to the average load and
maintain steady conditions ( i.e. Boiler Master in manual )

Have the plant operator adjust the air flow to the standard %O2
below. Maintain safe firing by using good boiler operating
practice (i.e. monitor Combustibles / CO in stack and/or visual
combustion checks)

Excess O2, %:
Stack Temp:
Ambient Air Temp:

5.0
540
80

Excess O2, %*:


Stack Temp,F:
Ambient Air Temp:

Deg F
Deg F

2.8%
500
80

Deg F
Deg F

*Standard Excess O2 per Fuel type ( >50% Load, at Burner)

Sensible Heat Loss =


Latent Heat Loss =
Radiation Loss =
Unaccounted For Loss =
Boiler Efficiency =

12.4%
5.0%
0.8%
1.0%
80.8%

Sensible Heat Loss =


Latent Heat Loss =
Radiation Loss =
Unaccounted For Loss =
Boiler Efficiency =

Boiler Efficiency Gain

= 2.7%

Payback Analysis:
Enter Project Cost, $:

$12,000

Enter Fuel Bill, $:


Annual Savings %
Efficiency Savings:
Project Payback:

$100,000
2.7%
$32,313
3.7

Note: the average installed cost of a TrimPAK system, including VFD, is $12,000

monthly

months

This calculation does not take into account savings from reduced maintance and failure avoidance, or reduction
in electricity consumption when installing a Variable Speed Drive.

9.7%
5.0%
0.8%
1.0%
83.5%

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