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 200 BHp

Annual Fuel Requirement 27,518 MM Btu/Yr Based on load profile as shown in graph below

Potential savings goal 4.0% expected increase in efficiency, per boiler

Use the Boiler Efficiency Calculator to estimate efficiency gain!

Electricity Natural Gas Heating Oil Coal

kwh decatherm gallon ton
Cost/unit of energy $0.10 $10.00 $1.85 $54.00
Cost/MM BTU $29.30 $10.00 $13.70 $2.25
Annual fuel cost/boiler $806,282 $275,184 $377,104 $61,916
Savings $32,251 $11,007 $15,084 $2,477 per boiler, per year

Heating Month vs Pct Load

120%

100%

80%

60% % Load

40%

20%

0%
L G P T V C N B R R AY UN
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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 100 Bhp
Efficiency 80.0%

Average Load 80.0%

Hrs/day in use 16
Days/Yr in use 200

Annual Fuel Requirement 10,720 MM Btu/Yr

Potential savings goal 4.0% expected increase in efficiency, per boiler

Use our Boiler Efficiency Calculator to estimate efficiency gain!

Electricity Natural Gas No. 2 Oil No. 6 Oil Coal

kwh decatherm gallon gallon ton
Cost/unit of energy $0.10 $10.00 $1.85 $1.10 $54.00
Cost/MM BTU $29.30 $10.00 $13.70 $7.33 $2.25
Annual fuel cost/boiler $314,093 $107,200 $146,904 $78,613 $24,120
Savings $12,564 $4,288 $5,876 $3,145 $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:
Units:
Boiler Rating 75 1000 lbs/hr Percent Load
Average Load 60 1000 lbs/hr 80.0%
Fuel Type: No. 6 Oil
Coal % H2O 5 If coal or solid is selected as fuel type, enter % moisture as fired.

Latent Loss = 5.0%

From ABMA Chart. Note: Assumes 4 Water Cooled Walls in Furnace.
RadiationLoss = 0.8% 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 Have the plant operator adjust the air flow to the standard %O2
maintain steady conditions ( i.e. Boiler Master in manual ) below. Maintain safe firing by using good boiler operating
practice (i.e. monitor Combustibles / CO in stack and/or visual
combustion checks)

Excess O2, %: 5.0 Excess O2, %*: 2.8%

Stack Temp: 540 Deg F Stack Temp,F: 500 Deg F
Ambient Air Temp: 80 Deg F Ambient Air Temp: 80 Deg F
*Standard Excess O2 per Fuel type ( >50% Load, at Burner)

Sensible Heat Loss = 12.4% Sensible Heat Loss = 9.7%

Latent Heat Loss = 5.0% Latent Heat Loss = 5.0%
Radiation Loss = 0.8% Radiation Loss = 0.8%
Unaccounted For Loss = 1.0% Unaccounted For Loss = 1.0%
Boiler Efficiency = 80.8% Boiler Efficiency = 83.5%

Boiler Efficiency Gain = 2.7%

Payback Analysis:
Enter Project Cost, $: $12,000 Note: the average installed cost of a TrimPAK system, including VFD, is $12,000

Enter Fuel Bill, $: $100,000 monthly

Annual Savings % 2.7%
Efficiency Savings: $32,313
Project Payback: 3.7 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.