Fuel costs are only one piece of the puzzle
Fuel may dominate a boiler’s operating budget, but it is just one lever in the complex chain of steam generation. “Air-to-fuel balance, heat losses and operator skill all interact. Managing those moving parts in real time demands specialist oversight,” says Gavin Evezard, Projects Director at Associated Energy Services (AES).
Why outsource thermal combustion optimisation?
Plants whose core business is manufacturing rarely have the time, resources or deep experience needed to run high-performance steam systems. Dennis Williams, Commercial Director at AES, notes:
“Our teams operate more boilers than any single client. We apply one proven standard across every site and pass new learnings straight on.”
Because AES sells steam at a guaranteed Rand-per-ton price, the company carries the performance risk – covering any shortfall itself. That commercial model keeps total energy-plant cost visible and predictable.
Common steam-plant pitfalls
A site audit often uncovers hidden losses:
- Fuel-oil sludge blocking filters and burners.
- Air leaks that push hot gases – and profit – up the stack.
- Under-grate dampers and draft controls left uncalibrated.
- Emission-abatement systems running below spec.
“These issues seldom surface until an unscheduled outage occurs,” Williams says. “Taking a boiler off-line is when we find the real opportunities to optimise.”
Data-driven improvements
“If we don’t measure it, we can’t manage it,” Evezard emphasises. AES logs every critical variable—oxygen, stack temperature, blow-down rate, water chemistry—and turns that data into actionable insights. While remote monitoring and AI already help on gas- and oil-fired units, coal systems still need experienced operators to respond to fluctuating fuel quality.
Proven results: Up to 35 % efficiency gains
A recent multi-site engagement delivered 21 % fuel savings at one plant and 35 % at another through thermal combustion optimisation alone. Further gains are achieved by improving condensate return, water treatment and overall boiler-house management.
Safety and compliance built in
Combustion excellence is inseparable from safety. AES follows ISO 9001, 14001 and 45001 standards, runs routine statutory inspections and insists on surplus boiler capacity wherever possible so equipment can be rotated for maintenance without halting production.
Founded 25 years ago, AES is South Africa’s leading specialist in steam and boiler operations and maintenance. The company supports clients in power generation, chemicals, pulp and paper, food and beverage, mining and more. Core services include:
- Risk mitigation and downtime reduction
- Efficient fuel procurement and combustion tuning
- Asset-lifetime care and energy-mix diversification
- Site-operations improvement and carbon-footprint reduction
AES invests heavily in training and equal-opportunity development, believing that sustainable industry growth benefits both communities and the environment.
