Industrial Steam Boiler and Heating Systems

The Basics of Industrial Steam Boiler Systems

Before we start discussing the Industrial Steam Boiler, let’s describe what a boiler is and how it works.

A Boiler is a closed container in which water or other suitable fluid/liquid is heated to generate steam or vapour. The steam/vapour is then departed and is used for different purposes like heating applications (water heating, central heating), boiler based power generation or even for cooking and other purposes which could be industrial or domestic.

Now let’s discuss about Industrial Steam Boiler Systems

Factories, hospitals, universities, laundry services, food processing services, breweries, etc. All of these industries and several others depend on some type of steam boiler system to deliver heat and/or hot water for their processes. However, not all industrial boiler systems are similar, nor is one type or size boiler system perfect for the requirements of every facility.

Whether you are installing a boiler in a brand-new building or changing an aging boiler in a current facility, here are the essentials you must know in order to make an informed choice about what is right for your requirements.

What is an Industrial Steam Boiler?

Industrial steam boilers have been a beneficial energy source for several centuries. With a modest setup, a steam boiler system combines water and heat to generate pressurized steam that is effortlessly used for indoor heating, powering engines and more. In industrial applications, the main function of a steam boiler is to produce, store, and transport the steam. Heat energy generated from burning the fuel heats the water within a cylindrical vessel. As a result, the boiler generates steam at the anticipated temperature and pressure.

Industrial Steam Boiler Price List

Working of Industrial Steam Boiler

The basic steam boiler working principle is extremely simple and easy to understand. The steam boiler is basically a closed vessel inside which water is deposited. Fuel (mostly coal) is burnt in a furnace and hot gasses are generated.

These generated hot gases come in contact with water vessels where the heat of these hot gases transmit to water and therefore steam is produced in the boiler.

Then this steam is supplied to the turbine of the thermal power plant through pipes. There are several different types of steam boiler heating system used for different purposes like running a production division, sanitizing some area, disinfecting equipment, to warm up the environment etc.

What are the different types of steam boilers?

Gas Fired Non IBR Steam Boilers: – Gas steam boilers are powered by propane or natural gas and are more proficient than standard boilers. The fuel for a gas fired boiler is supplied into the boiler from an external source that is connected directly to the boiler. The dispersal of heat using a gas steam boiler depends on its configuration. Gas fired steam boilers can be used for industrial purposes and low pressure applications.

 Oil Fired Non IBR Steam Boilers: –  Oil steam boilers operate on the same principles as gas boilers; oil is ignited in the combustion compartment instead of gas. The burning oil heats the exchanger that heats the water. Oil fired steam boilers can extend to an efficiency of over 90%. Though they are more affluent than gas steam boilers, they incline to have twice the lifespan of a gas boiler.

Electrical/Electrode Non IBR Steam Boilers: – Electrical/Electrode Steam Boilers are an exclusive type of boilers where you do not have to worry about any fuel and its management problems because they do not use any fuel for heating. These Industrial steam boilers need electrodes which act as a good conductor to transmit electricity from main supplies to water. Electrical/Electrode Steam Boilers work on a principle of electrical resistance and here water acts as a resistance in the path of electricity.

The Parts and Functioning of Industrial Steam Boiler

However not every steam boiler is the same but there are basic elements that are common to all steam boilers: burner, combustion chamber, heat exchanger, expansion tank, steam temperature control, safety relief valve, and low water cut-off.

List of Parts and their function: –
Burner: – The purpose of the burner is to inject fuel and air into the combustion region. The fuels, such as oil, gas, or pulverized coal, have to blend easily with air. Dampers are used to control the amount of air that enters the burner. An impeller circulates the air equally around the burner. Pipes mentioned as spuds inject the fuel into the boiler and are ignited by an igniter.

Combustion Chamber: – The combustion compartment comprehends the reaction of the fuel with air and uses it to produce the heat to generate steam. To increase the efficiency of the combustion chamber, it needs to be sufficiently insulated to prevent loss of heat through radiation. The combustion chamber has tubes comprising water and steam that pass through the open box with the burner and controls. The heat produced in the combustion compartment is absorbed on the surface of the boiler at the top of the combustion chamber.

Heat Exchanger: – The heat exchanger enables heat to be exchanged between fluids without allowing the elements to mix. A heat exchanger contains an extensive coiled pipe that is submerged in the fluid to be heated. Heated liquid or gas passes through the pipe and heats the water around it. Heat exchangers are made from a variety of materials with stainless steel being the top material since it does not rust or corrode.

Expansion Tank: – The expansion tank aids to uphold the pressure in a boiler by providing a place for water to expand, absorb the pressure, and control the pressure. The tank has a diaphragm that is divided into two segments with one portion accepting water from the boiler and the other side being controlled by an air valve to alleviate pressure. The air valve pushes against the water in the other segment until normal pressure is reached.

Steam Temperature Control: – Steam temperature control avoids thermal stress; accurate control of steam temperature is essential. The control of pressure and temperature is essential to keep fuel costs down. Steam temperature is generally controlled by spraying water on the first and second stage superheater. This is done using an attemperator or desuperheater.

Safety Relief Valve: – The pressure relief valve is the most significant safety measure for steam boiler use. It ensures that the build-up of pressure in a steam boiler system will be relieved; this helps in preventing a tragic disaster. The pressure relief valve opens when the pressure reaches a critical level and closes when the pressure returns to normal.

Low Water Cut-off: – A low water cut-off switches off the burner or shuts off fuel to a steam boiler when the water level drops below a set point. A dry fired boiler can break or undergo substantial failure. Low water cut-offs are another safety feature fabricated into a steam boiler to help prevent damage and harm to the boiler. They are a regular part of boiler construction and are installed in steam boiler systems and hydronic devices to shut down the boiler in the case of the loss of water.

*Note: – The designs and types of steam boilers extensively differ depending on their construction and purpose.

Applications of Industrial Steam Boiler Systems

The traditional purpose of steam boilers is to assist as central heating for offices, homes, businesses, hospitals, and other facilities. Irrespective of where they are used, all boilers have the same basic functions and mechanisms that function as a contained heat generating combustion procedure.

There are a wide range of fuels used to produce heat in a boiler to ignite the burner. The created heat travels through the system using pumps and heat exchangers. In order to specify the function of a steam boiler, extra control mechanisms are added.

Some of the major application industries are as follows: –

Power Generation: – One of the functions of a steam boiler is to power turbines to produce electricity. An extremely powerful and large boiler can generate as much as 225,000 pounds of steam per hour at 900 psi. A steam boiler system of that size can generate 20 megawatts of electricity. With technical upgrades and innovations, industrial steam boilers can be designed to save on energy while producing it.

Laboratories: – Laboratories on college campuses use exhaust air when testing and experimenting. To replace the exhausted air, experimenters bring in outside air that can be cold, so they need heating. Since labs are large and spacious, an extensive amount of heat is necessary to heat them. In order to meet the requirement, universities and colleges use low pressure steam boilers.

Food and Beverage: – Pasteurization needs products be heated at fixed temperatures to eliminate pathogens. If the temperature is not accurately controlled, the taste of the final product can be damaged. Brewers and distillers use low pressure steam heat to produce constant batches at a low cost. Dairy producers use steam boilers for cleaning and sanitization.

Aquariums: – Aquariums use steam boiler systems to power their processes. The countless tanks required to function an aquarium have to have the water temperature and water conditions wisely regulated to protect the extensive varieties of species that are on display. Gas powered steam boilers are used with heat exchangers to control fresh and saltwater tanks as well as deliver water currents and surges to create ocean like environments.

Lumber Kilns: – Low pressure steam boilers are used in the lumber industry for kilns used to dry specialty lumber products. Hardwoods used for making furniture and cedar planks used for cooking need drying in a kiln. A low pressure steam boiler allows producers to implement the drying procedure safely and efficiently to increase the quality of wood products. Since low pressure steam heat is manageable and extremely consistent, it is perfect for this type of drying procedure.

Frequently Asked Questions

What are the 2 types of steam heating system?
There are two basic boiler styles for steam boilers in this range, Watertube and Firetube boilers. As their names indicate, the Firetube boiler has the fire (combustion gases) inside the tube and the Watertube boiler has the water inside the tube.

What are the 3 types of boilers?
The three common types of steam boilers are Gas fired, Oil fired and Electrical steam boilers.

How many types of industrial boilers are there?
Industrial boiler systems include industrial hot water boilers, industrial steam boilers, industrial heat recovery and waste heat boilers.

What are the two main parts of a boiler?
The two main parts of all boilers are the burner and combustion chamber.

Which is the best boiler in India?
Ascent Machineries, Backed by over 20 years of boiler-making experience, has risen to the top of the list of best steam boiler manufacturers in India.