How to optimize Boiler Load management and rightsizing? (Energy Efficiency Tip of the Day)

Spread the Knowledge

How to optimize Boiler Load management and rightsizing?  (Energy Efficiency Tip of the Day)

Tip summary

    • An oversized boiler will turn on and off more often than a boiler that has been properly matched to the demand, which may result in short-cycling losses.
    • If the boiler is instead left on standby, short-cycling losses will be avoided but energy will be wasted in keeping the boiler on standby.
    • The main reason for energy losses at standby mode for the boiler is the lost amount of heat required to heat the boiler casing at this mode.
    • Rather than sizing a boiler to meet the highest possible load, fuel savings can be achieved by adding a smaller boiler sized to meet the plant’s average loads, or by using multiple small boilers.
    • Multiple small boilers offer reliability and flexibility to operators to follow load swings without over-firing and short cycling.
    • Load management also helps to reduce load variation. As this measure is normally an end-of-life option there should be no incremental costs to right size a boiler but a benefit exists by purchasing a smaller boiler.

Proposed actions

    • Evaluate your current boiler load management strategy.
    • For multi boilers systems, try to adjust steam demand to keep and boilers loads to keep the selected boiler running with acceptable load for long time (without steam venting).
    • The load management could be done manually by changing the current operating procedures or automatically by modifying boilers load control.
    • Consider/evaluate installing a small boiler to cover small load periods instead of operating large boiler at low load.


    • System tuning will have low cost.
    • New small boiler addition will have medium cost but quick ROI.


    • Estimated energy savings range: 10-50% of boiler energy use.
    • Decrease equivalent amount of boiler load and decrease CO2 emissions accordingly to save the environment.


    • Boilers Load Management Assessment could save up to 50% of boiler energy use.
    • The load management is easy to implement with low cost for proper control modifications.
    • Please share this tip with others to share knowledge and increase energy efficiency awareness.
    • Please contact me for any advice or support about this issue or other energy management issues.

Tip video

Link to download tip slides

Tip video Arabic version


My blog


#Energy #energyefficiency #energymanagement #steam #steamsystem #sustainable #sustainability #engineering #engineer #chemicalengineering #boiler #360practiveengineer #loadmanagement #steamboiler  # EnergyEfficiencyTipoftheDay


Magdy Aly

Energy manager, Energy efficiency consultant Passionate to help others to save Energy and Environment.

You may also like...

Leave a Reply

Your email address will not be published. Required fields are marked *