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

Annual Fuel Requirement
Potential savings goal

Cost/unit of energy
Cost/MM BTU
Annual fuel cost/boiler
Savings

200 BHp
27,518 MM Btu/Yr

Based on load profile as shown in graph below

4.0% expected increase in efficiency, per boiler

Use the Boiler Efficiency Calculator to estimate efficiency gain!
Electricity Natural Gas Heating Oil
kwh
decatherm
gallon
$0.10
$10.00
$1.85
$29.30
$10.00
$13.70
$806,282
$275,184
$377,104
$32,251
$11,007
$15,084

Coal
ton
$54.00
$2.25
$61,916
$2,477 per boiler, per year

Heating M onth vs Pct Load

120%
100%
80%
60%
40%
20%
0%

% Load

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

Efficiency

100 Bhp
80.0%

Average Load

80.0%

Hrs/day in use
Days/Yr in use

16
200

Annual Fuel Requirement

Potential savings goal

Cost/unit of energy
Cost/MM BTU
Annual fuel cost/boiler
Savings

10,720 MM Btu/Yr
4.0% expected increase in efficiency, per boiler
Use our Boiler Efficiency Calculator to estimate efficiency gain!
Electricity Natural Gas
kwh
decatherm
$0.10
$10.00
$29.30
$10.00
$314,093
$107,200
$12,564
$4,288

No. 2 Oil
gallon
$1.85
$13.70
$146,904
$5,876

No. 6 Oil
gallon
$1.10
$7.33
$78,613
$3,145

Coal
ton
$54.00
$2.25
$24,120
$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:
Boiler Rating
Average Load
Fuel Type:
Coal % H2O

75
60
No. 6 Oil
5

Units:
1000 lbs/hr
1000 lbs/hr

Percent Load
80.0%

If coal or solid is selected as fuel type, enter % moisture as fired.

Latent Loss =

5.0%

RadiationLoss =

0.8%

From ABMA Chart. Note: Assumes 4 Water Cooled Walls in Furnace.

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
maintain steady conditions ( i.e. Boiler Master in manual )

Have the plant operator adjust the air flow to the standard %O2
below. Maintain safe firing by using good boiler operating
practice (i.e. monitor Combustibles / CO in stack and/or visual
combustion checks)

Excess O2, %:
Stack Temp:
Ambient Air Temp:

5.0
540
80

Excess O2, %*:

Stack Temp,F:
Ambient Air Temp:

Deg F
Deg F

2.8%
500
80

Deg F
Deg F

*Standard Excess O2 per Fuel type ( >50% Load, at Burner)

Sensible Heat Loss =

Latent Heat Loss =
Radiation Loss =
Unaccounted For Loss =
Boiler Efficiency =

12.4%
5.0%
0.8%
1.0%
80.8%

Sensible Heat Loss =

Latent Heat Loss =
Radiation Loss =
Unaccounted For Loss =
Boiler Efficiency =

Boiler Efficiency Gain

= 2.7%

Payback Analysis:
Enter Project Cost, $:

$12,000

Enter Fuel Bill, $:

Annual Savings %
Efficiency Savings:
Project Payback:

$100,000
2.7%
$32,313
3.7

Note: the average installed cost of a TrimPAK system, including VFD, is $12,000

monthly

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.

9.7%
5.0%
0.8%
1.0%
83.5%