Hello, Dear Customer!
On this page, we have attempted to calculate your potential losses based on the types of deposits that may form on the heat transfer surface of your steam boiler. These calculations are for informational purposes only and are based on certain assumptions.
Note: This module is currently in the testing phase!
We recommend that you contact your sales representative for more detailed information.
Please enter the values carefully and click the “Calculate” button to obtain the technical result.
Steam Boiler Scale Loss Calculator
Annual additional fuel cost • USD • Preliminary assessment
1. Boiler and production details
Area determines deposit volume only. Steam production, pressure, steam type and feedwater temperature document operating conditions; this version does not derive fuel consumption or steam enthalpy from them. Actual fuel consumption is required below to calculate cost.
2. Deposit and calculation method
The DOE table applies only to fire-tube boilers without flue-gas heat recovery. For calcium carbonate, the normal-scale curve is only an approximate reference, not a validated relationship for pure CaCO₃. Normal scale is generally associated with low-pressure service, and iron-rich categories with high-pressure service; the source provides no exact pressure cutoff.
Clean consumption must be measured at the SAME steam production, pressure, steam quality/superheat, feedwater temperature, blowdown rate, fuel and combustion settings. Otherwise the full difference cannot be attributed to deposits. Do not substitute nameplate capacity for actual production.
3. Fuel consumption and price
Price and consumption must use the same unit. For natural gas, do not mix Nm³ and Sm³ reference conditions; use the billing definition. Convert local-currency prices to USD per unit first. No automatic heating-value conversion is performed between fuels.
Fields start empty. Enter your operating data to calculate.
Annual additional fuel cost
Loss as a share of current fuel use
Annual additional fuel quantity
| Calculation method | |
|---|---|
| Operating conditions | |
| Current annual fuel cost | |
| Deposit volume (uniform thickness assumed) | |
| Current specific fuel consumption | |
| Consumption difference from clean reference |
How is this calculated?
The annual estimate assumes constant thickness, production, hourly consumption and price throughout the operating period. If scale grows during the year, calculate periods separately and add them. The loss fraction is not a percentage-point drop in boiler efficiency. Production losses, maintenance, failures, downtime and cleaning costs are excluded. Attribution of measured consumption differences solely to deposits must be verified separately.
Source: U.S. Department of Energy, Steam Tip Sheet #7 (2012)
