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potential natural gas savings of more than 25,000 MMBtu annually if the boilers at the Caldwell facility could be operated consistently at a flue gas oxygen level of 3%. This could be accomplished by upgrading the aging burners and controls and installing flue gas oxygen trim systems on the boilers, as indicated in the earlier analysis.
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A boiler fired with natural gas costing $8.00/MMBtu produces 450-pounds-per- square-inch-gauge (psig) saturated steam and is supplied with 230°F feedwater. Using values from the tables, calculate the fuel cost of producing steam.
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Over a typical 10 year operating period of a boiler, a misunderstanding of boiler efficiency can accumulate to represent over $5 million of missed potential savings. Calculations based on 10 tonne boiler, operating at 10 bar g, feedwater at 80°C, operating for 6000 hours per year, Natural Gas at $4.93/kWh (based on average Gas price in 2013
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(MMBtu) of natural gas while producing 45,000 lb/hour of 150-psig steam. Stack gas measurements indicate an excess air level of 44.9% with a flue gas minus combustion air temperature of 400°F. From the table, the boiler combustion efficiency is 78.2% (E1). Tuning the boiler reduces the excess air to 9.5% with a flue gas minus combustion
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