Boiler Combustion Efficiency Calculator

Boiler Combustion Efficiency Formula:

\[ \eta = \frac{CO_2\% \times \text{Fuel Factor}}{\text{Theoretical Air}} \times 100 \]

Combustion Efficiency (η):

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1. What is Boiler Combustion Efficiency?

Boiler combustion efficiency measures how effectively a boiler converts fuel into usable heat energy. It represents the percentage of fuel energy that is actually utilized for heating, with the remainder lost through flue gases and other inefficiencies.

2. How Does the Calculator Work?

The calculator uses the combustion efficiency formula:

\[ \eta = \frac{CO_2\% \times \text{Fuel Factor}}{\text{Theoretical Air}} \times 100 \]

Where:

\( CO_2\% \) — Carbon dioxide percentage in flue gas
\( \text{Fuel Factor} \) — Dimensionless factor specific to fuel type
\( \text{Theoretical Air} \) — Theoretical air required for complete combustion
\( \eta \) — Combustion efficiency percentage

Explanation: This formula calculates efficiency based on flue gas analysis, where CO₂ concentration indicates combustion completeness and the fuel factor accounts for specific fuel characteristics.

3. Importance of Combustion Efficiency

Details: High combustion efficiency reduces fuel consumption, lowers operating costs, decreases emissions, and extends equipment lifespan. Regular efficiency monitoring helps identify maintenance needs and optimize boiler performance.

4. Using the Calculator

Tips: Enter CO₂ percentage from flue gas analysis, fuel factor specific to your fuel type, and theoretical air percentage. All values must be positive numbers. CO₂ percentage should be between 0-100%.

5. Frequently Asked Questions (FAQ)

Q1: What is a typical fuel factor value?
A: Fuel factors vary by fuel type: natural gas (~0.9-1.1), fuel oil (~0.8-1.0), coal (~0.7-0.9). Consult fuel specifications for exact values.

Q2: How is theoretical air determined?
A: Theoretical air is calculated based on fuel composition and stoichiometric requirements for complete combustion, typically provided in fuel analysis reports.

Q3: What is considered good combustion efficiency?
A: Modern boilers typically achieve 85-95% efficiency. Values below 80% indicate potential issues requiring investigation and maintenance.

Q4: Why use flue gas analysis for efficiency calculation?
A: Flue gas composition directly reflects combustion quality. CO₂ levels indicate how completely fuel is burning, while oxygen levels show excess air.

Q5: How often should efficiency be measured?
A: Regular monitoring (monthly or quarterly) is recommended, with additional measurements after maintenance, fuel changes, or when performance issues are suspected.