The Mid-Level Thermodynamics Engineer – Boiler Heat Transfer is responsible for analyzing, modeling, and improving the thermal performance of boiler systems and steam generation processes. This role involves detailed technical assessments of heat transfer efficiency, combustion dynamics, and energy losses across utility and industrial boilers. The engineer supports performance monitoring, troubleshooting, design enhancements, and plant efficiency initiatives.
Perform detailed heat transfer analysis (conduction, convection, radiation) across boiler pressure parts such as economizers, superheaters, reheaters, and waterwalls.
Develop and refine thermal models and simulations to assess and optimize heat flux distribution and boiler efficiency.
Conduct energy balance calculations, Rankine cycle evaluations, and identify opportunities for heat recovery and performance improvement.
Monitor and evaluate boiler performance data using SCADA, DCS, and data historian systems.
Support root cause analysis (RCA) of thermal inefficiencies, fouling, slagging, or overheating issues.
Assist in the design and specification of thermal upgrades, including material selection, burner configuration, and retrofit recommendations.
Provide technical support for commissioning, tuning, and thermal acceptance testing of boiler systems (ASME PTC 4 compliance).
Collaborate with operations, maintenance, and process teams to align thermal performance with operational targets.
Prepare technical reports, documentation, and performance tracking dashboards.
Boiler Heat Transfer Optimization
Focus on increasing boiler thermal efficiency by improving heat exchange surfaces and minimizing losses.
Thermodynamic Performance Modeling
Use of tools such as MATLAB, EES, Aspen Plus, or custom Excel models to simulate and predict performance under varying load and fuel conditions.
Energy Recovery & Efficiency Improvement
Evaluate opportunities for waste heat recovery, air preheating, condensate reuse, and low-grade heat utilization.
Performance Monitoring & Diagnostics
Trend analysis and performance benchmarking to detect performance drift or degradation over time.
Compliance & Testing Support
Support for ASME PTC 4 performance testing and boiler efficiency standards compliance in coordination with QA and regulatory teams.
Bachelor’s degree in Mechanical Engineering or Thermal Engineering (Master’s preferred).
3–7 years of experience in boiler systems, thermal design, or heat transfer engineering.
Solid understanding of thermodynamics, heat transfer, and combustion principles.
Proficiency in thermal modeling tools and performance monitoring platforms.
Working knowledge of boiler codes and standards (ASME, API, PTC).
Strong analytical and communication skills with a data-driven mindset.