BOILERS, PUMPS & VALVES W
ith energy prices under pressure and production demands constantly changing, getting more from your steam boiler is essential. Ben shares practical
insights into improving steam boiler efficiency, reducing energy waste and achieving measurable cost and emission savings. When considering a new steam installation,
whether for purchase or rent, selecting the right boiler for the application is critical to avoid unnecessary energy use and cost. The starting point should be a simple question: do you know your actual steam demand? It is not uncommon for boilers onsite, or
those specified for rental jobs, to be larger than required. This can be the result of legacy systems, historic assumptions or a tendency to specify a like-for-like replacement without accounting for changes in production processes or advances in boiler technology. Understanding how much steam a site genuinely needs is, therefore, an important first step towards improving efficiency. In a steam boiler, energy is supplied
by combusting a fuel-air mixture. Heat is transferred to the water through radiation, conduction and convection, producing the steam required by the process. The efficiency of that process depends on how effectively the available energy is converted into useful steam. Conventional industrial steam boilers
typically operate at around 85 per cent efficiency. In other words, approximately 15 per cent of the energy contained in the fuel can be lost through radiation, burner purges and exhaust gases discharged through the flue. While some losses are unavoidable, there are opportunities to recover or reduce them.
RECOVER HEAT – REDUCE COSTS Recovering otherwise wasted heat can reduce fuel consumption, emissions and operating costs. Depending on the process and the technology employed, recovered heat can also be redirected to other operations on the same site, or potentially used elsewhere. One of the most established approaches
is the use of an economiser. This heat exchanger transfers energy from the boiler’s flue gases into the incoming feedwater. By preheating the feedwater, less energy is required from the burner to produce the same quantity of steam.
THE HEAT IS ON: GETTING MORE FROM STEAM GENERATION
By Ben Friend, Steam Sales Engineer, Atlas Copco Rental UK and Ireland
Steam generation can be one of the biggest energy costs in an industrial operation, making boiler efficiency critical to both the bottom line and emissions targets
The potential impact is significant. A
reduction of around 5 per cent in fuel consumption can translate directly into lower energy costs, while also reducing associated CO2 and NOx emissions. The potential savings from heat recovery
will naturally depend on the scale of the boiler and its operation. However, heat recovery should not be viewed as something reserved for larger installations. For example, our newest and ‘smallest’ plug and steam boiler is 95 per cent efficient as it includes an integrated smoke economiser, amongst other efficient factors.
LOOK BEYOND THE BOILER Heat recovery is only one part of improving steam system efficiency. Burner technology can also play an important role. Variable Speed Drive (VSD) burners can adjust fuel and air supply according to changing load demand, while oxygen regulation systems can monitor flue-gas oxygen levels and adjust combustion accordingly. Condensate recovery is another important
consideration. Returning condensate to the boiler reduces the energy required to heat incoming water and can also reduce water
16 SEPTEMBER 2026 | FACTORY&HANDLINGSOLUTIONS
and chemical consumption. The wider lesson is that steam efficiency
should not be assessed by the boiler alone. Understanding actual demand, matching capacity to that demand, recovering available heat and optimising combustion can all contribute to a more efficient system. As energy costs and decarbonisation
pressures continue to shape industrial decision-making, taking a closer look at how steam is generated and where energy is being lost could be one of the simplest ways to identify meaningful efficiency gains. Furthermore, a dual fuel burner can
operate on natural gas or oil, supporting efforts to reduce NOx. And a further way to recover heat is to collect blowdown condensate once it cools and returns to water and return this back to the boiler for reuse. This can further contribute to energy efficiency and reduce water costs.
Atlas Copco
www.atlascopcorental.com
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