Energy Efficiency in Industrial Facilities: Start with Boilers

Energy Efficiency in Industrial Facilities: Start with Boilers

The Role of Boilers in Industrial Energy Use

In energy-intensive industries such as textiles, food, chemicals, pharmaceuticals, and automotive, steam and hot-water boilers can account for 40–60% of total energy costs. This makes them the prime target for efficiency upgrades.

Common Causes of Inefficiency

  • Poor burner adjustment → leads to incomplete combustion and wasted fuel.
  • Fouled heat exchangers → reduce heat transfer and raise flue gas temperatures.
  • Insufficient insulation → causes up to 10% energy losses in piping.
  • Manual controls → cannot react quickly to fluctuating loads, resulting in unnecessary operation.

Five Strategies for Efficiency

  1. Advanced Automation & Control Systems
    PLC-based panels monitor boiler loads and adjust burner output in real time, ensuring steady operation and reducing fuel consumption.
  2. Heat Recovery Solutions
    Flue gas economisers preheat feed water with waste heat, yielding 5–10% fuel savings. Condensing technology captures latent heat from water vapour for additional efficiency.
  3. Proper Insulation
    Applying insulation to pipes, tanks, and fittings prevents heat loss and saves thousands of euros annually in large facilities.
  4. Digital Monitoring & Analytics
    IoT-enabled sensors provide continuous tracking of temperature, pressure, flow, and flue gases. Energy management software transforms this data into actionable insights.
  5. Preventive Maintenance
    Annual servicing detects issues before they cause costly downtime. Maintenance not only avoids failures but also preserves long-term efficiency.

Case Studies

  • Textile Plant: Automation upgrade reduced natural gas consumption by 12%.
  • Food Factory: Flue gas economiser installation saved over €15,000 annually.
  • Chemical Facility: Pipe insulation retrofit reduced total energy use by 8%.

Conclusion

Energy efficiency projects reduce operational costs and contribute to sustainability. YGT ISI provides tailored automation, maintenance, and modernisation solutions, ensuring both immediate savings and long-term resilience for industrial facilities.