Energy Efficiency Enhancement for Industrial Boilers Utilizing High Emissivity Coating: A Case Study

Abstract

The growing energy demand has driven a consistent rise in energy costs, making energy conservation imperative, particularly in the industrial sector due to its significant energy consumption. Boilers are critical in various industries and other economic sectors that rely on heat energy. Currently, more than 10,000 boilers are registered with the Thai Department of Industrial Works and a global market exceeding 500 trillion baht. Consequently, improving boiler efficiency has become both critical and urgent. This study explores the application of high-emissivity coatings to enhance boiler efficiency. These coatings, by reducing heat loss from reflection and increasing heat absorption in boiler water tubes, improve heat transfer to steam. This results in enhanced boiler performance, enabling increased production and reduced fuel consumption. The findings reveal that high-emissivity coatings can improve boiler efficiency from 89.61% to 91.67%, achieving energy savings of 2.25% or 3.05 GJ/h. This leads to an annual reduction in fuel consumption by 488.57 tons and carbon emissions by 1,315.61 tons, all without compromising steam output. These outcomes were validated through hypothesis testing. This measure provides a practical solution to energy challenges and can be implemented alongside other efficiency improvement measures. Moreover, it strengthens industrial competitiveness and aligns with environmental sustainability goals.