Save on fuel when running diesel boilers

Top fuel-saving actions

To gain efficiency and reduce costs, regularly check, tune and service your boiler to ensure peak performance.  

Being proactive about maintenance will protect your investment and prevent small issues from adding up to large costs over time.

Carry out weekly boiler efficiency checks 

To identify inefficiencies that could be costing you money, carry out regular inspections.   

• Check for steam leaks. 
• Check for and clean out excess carbon build up or clogs. 
• Test steam traps. 
• Test combustion efficiency.  
• See if the fuel tank contains sludge. 
• Check pressure settings are correct. 

Address any issues quickly to avoid downtime costs, damage to your asset or voiding a warranty. 

Prioritise boiler maintenance 

To operate efficiently, last longer and remain safe to run, your boiler needs regular servicing and maintenance.  

• Get your boiler tuned by a qualified technician.  
• Clean your boiler (both fireside and waterside). 
• Repair steam traps to maintain efficiency and performance. 

Find ways to reduce fuel demand 

These checks and processes can result in using less diesel when running your boiler.  

• Insulate all steam and condensate lines. Use removable thermal jackets for valves and fittings if cladding prevents easy access. 
• Operate the minimum number of boilers required and reschedule peak loads. 
• Ensure your boiler is the right size for your process, so you’re not wasting fuel.  

Before purchasing or replacing an existing boiler, look at how you could reduce heat demand. For example, could you: 

• stagger processes that require heat 
• insulate pipes and equipment 
• install a heat recovery system 
• lower temperatures 
• serve lower heat loads with heat pumps or electric water heaters. 

Add boiler efficiency optimisers 

Consider these additional actions when possible, as they’ll further boost efficiency and fuel savings.  

• Maximise condensate return with economisers (5–10% efficiency savings). 
• Recover heat from blowdown water (it is often above 150°C so ideal for heat recovery). 
• Optimise boiler blowdown and cycle rates. 
• Install automatic air-fuel controls. 
• Install automatic blowdown control. Automatic controllers measure the total dissolved solids (TDS) level and blow down at the optimum rate.  

Consider shifting to a different type of boiler 

To reduce fuel costs for process heat, look into other options such as electric, biogas or biomass boilers. The following guide details the pros and cons of each boiler alternative, along with their capital and operating costs. 

Learn about clean alternatives for process heat