Oil vs Gas vs Biomass Fuel Consumption Comparison

In many boiler projects, the first question is surprisingly simple. Before discussing brands, control systems, or installation details, buyers usually want to know one thing:

How much fuel does a 4 ton steam boiler consume per hour?

The answer affects daily operating cost, fuel selection, and long-term investment planning. It also plays a role when estimating emissions and evaluating whether a boiler upgrade actually makes financial sense.

Below is a practical comparison based on commonly used industrial data, focusing on oil-fired, gas-fired, and biomass-fired boilers with a capacity of 4 tons of steam per hour.

What Does a "4 Ton Steam Boiler" Mean?

In simple terms, a 4 ton steam boiler means the unit can produce about 4,000 kg of steam every hour, often referred to as 4 TPH (tons per hour).

This size is widely seen in real production environments, including:

• Food processing plants
• Textile and garment factories
• Chemical and pharmaceutical workshops
• Feed mills and paper plants
• Small and medium-scale cogeneration systems

For many factories, this capacity sits right in the middle — large enough for continuous production, but still manageable in terms of space and fuel supply.

Basic Assumptions Used for Fuel Consumption Calculation

In real operation, results rarely match calculation values exactly. Installation quality, control logic, insulation condition, and even operator habits can all influence actual fuel consumption.

Energy Required to Produce 4 Tons of Steam per Hour

Producing saturated steam typically requires around 2,700–2,800 kJ per kilogram. Engineers usually work with an average value instead of the extreme ends of the range.

For a 4 TPH boiler, the total heat demand comes out to roughly:

4,000 kg × 2,750 kJ ≈ 11,000,000 kJ per hour (11 GJ/h)

This number is the reference point used in the fuel calculations below.

Fuel Consumption Comparison for a 4 TPH Steam Boiler

Diesel and Heavy Oil Consumption

Diesel oil has a heating value of about 42,000 kJ/kg, while heavy fuel oil is slightly lower, at around 40,000 kJ/kg.

For a 4 ton steam boiler running on diesel, hourly fuel consumption usually falls between 260 and 290 kg. Heavy oil consumption is often slightly lower, depending on burner setup and combustion tuning.

Oil-fired boilers are often chosen in locations without reliable gas supply or where fast startup is required. Fuel cost and emissions, however, are factors that most buyers carefully evaluate before making a decision.

Natural Gas Consumption

Natural gas boilers are known for clean combustion and precise load control. The lower heating value of natural gas typically ranges from 35,000 to 38,000 kJ per Nm³.

Under normal factory conditions, a 4 ton steam boiler usually consumes 300–330 Nm³ of natural gas per hour. The exact figure depends not only on efficiency, but also on how often the boiler operates at partial load instead of full capacity.

For plants with stable gas access, natural gas boilers often offer a good balance between operating cost, automation level, and environmental performance.

Biomass Fuel Consumption

Common biomass fuels include pellets, wood chips, rice husk, and palm shell. Biomass pellets generally have a heating value of 15,000–17,000 kJ/kg, while wood chips are lower and less consistent.

In most projects, a 4 ton biomass steam boiler consumes roughly:

• 800–950 kg per hour of biomass pellets
• 1,000–1,200 kg per hour of wood chips

Biomass systems are frequently selected in regions with abundant agricultural waste, where fuel cost is low and carbon reduction policies provide additional incentives.

Factors That Affect Actual Fuel Consumption

Even when boilers share the same rated capacity, fuel usage can differ noticeably. Common influencing factors include boiler age, steam pressure, feedwater temperature, and load fluctuation during daily operation.

It is not uncommon to see fuel consumption increase by 10–15% in systems with poor maintenance or unstable operating conditions.

Which Fuel Is More Suitable for a 4 Ton Steam Boiler?

In practice, the final choice usually depends on local conditions rather than theoretical efficiency alone. Fuel availability, price stability, and emission limits all play a role.

Final Remarks

For a 4 ton steam boiler, hourly fuel consumption is typically around:

• 260–290 kg of diesel oil
• 300–330 Nm³ of natural gas
• 800–1,200 kg of biomass fuel

For most buyers, these figures serve mainly as a starting reference. Actual decisions are usually made after checking local fuel prices, operating hours, and real steam demand on site.

Contact Us for More Information

If you have questions about choosing the right boiler or want a detailed fuel consumption estimate for your factory, feel free to reach out to us directly.

WhatsApp: +86 138 3852 9852

Our team is ready to provide personalized advice and help you select the most cost-effective and efficient solution for your steam system.