zozen boiler
Home Service FAQs Boiler basics What is the fuel-to-steam efficiency of an industrial boiler?

What is the fuel-to-steam efficiency of an industrial boiler?

31 Jan 2020

Fuel-to-steam efficiency is a measure of the overall efficiency of the boiler. It accounts for the effectiveness of the heat exchanger as well as the radiation and convection losses. It is an indication of the true boiler efficiency and should be the efficiency used in economic evaluations. As prescribed by the ASME Power Test Code, PTC 4.1, the fuel-to-steam efficiency of a boiler can be determined by two methods: the InputOutput Method and the Heat Loss Method.

Input-Output Method

The Input-Output efficiency measurement method is based on the ratio of the outputto-input of the boiler. It is calculated by dividing the boiler output (in BTUs) by the boiler input (in BTUs) and multiplying by 100. The actual input and output of the boiler are determined though instrumentation and the data is used in calculations that result in the fuel-to-steam efficiency.

Heat Loss Method

The Heat Balance efficiency measurement method is based on accounting for all the heat losses of the boiler. The actual measurement method consists of subtracting from 100 percent the total percent stack, radiation, and convection losses. The resulting value is the boiler's fuel-to-steam efficiency. The heat balance method accounts for stack losses and radiation and convection losses.

Stack Losses:

Stack temperature is a measure of the heat carried away by dry flue gases and the moisture loss. It is a good indicator of boiler efficiency. The stack temperature is the temperature of the combustion gases (dry and water vapor) leaving the boiler and reflects the energy that did not transfer from the fuel to the steam or hot water. The lower the stack temperature, the more effective the heat exchanger design, and the higher the fuel-to-steam efficiency.

Radiation and Convection Losses:

All boilers have radiation and convection losses. The losses represent heat radiating from the boiler (radiation losses) and heat lost due to air flowing across the boiler (convection losses). Radiation and convection losses, expressed in Btu/hr, are essentially constant throughout the firing range of a particular boiler, but vary between different boiler types, sizes, and operating pressures.

Related FAQs View More
Related news View More
  • ZOZEN Boiler: Empowering High-Quality Development in the Building Materials Industry
    The continuous growth of the building materials industry places higher demands on thermal energy supply in production—stable steam output, efficient energy utilization, and emissions that meet environmental standards have become core criteria for selecting boiler equipment. Leveraging a deep understanding of industry-specific production needs, ZOZEN Boiler provides customized products and technical advantages to deliver reliable thermal energy support for building materials enterprises at ...
    21 Oct 2025
  • ZOZEN Boiler Breaks the High Humidity Biomass Combustion Challenge with Reciprocating Grate Biomass Steam Boiler
    ZOZEN Boiler Breaks the High Humidity Biomass Combustion Challenge with DZW Series Reciprocating Grate Biomass Steam Boiler Recently, Jinzhi Morning Hong Paper Co., Ltd. (hereinafter referred to as "Morning Hong Paper") reached an important cooperation with ZOZEN Boiler, successfully introducing the DZW series reciprocating grate biomass steam boiler. This brings new impetus for efficient and green production to the company. As a leading paper product manufacturer in North China, Morning Hong P...
    14 Oct 2025
  • ZOZEN Boiler to Showcase at Heatpower Expo 2025 in Moscow, Russia
    From October 21 to 23, the Heatpower Expo, Russia’s premier industrial boiler and heat exchange exhibition, will be held at the Crocus International Expo Center. As a benchmark event in the industrial boiler and heat exchange equipment sector in Russia, the expo serves as both a window into industry trends and a high-energy platform for fostering practical cooperation. ZOZEN Boiler’s Russian-speaking sales team will participate with its core boiler solutions, demonstrating clean, eff...
    07 Oct 2025

Find the Right Boiler For You

Name *

Email *

WhatsApp/WeChat

Products

Power/Capacity