Steam Boilers

What do you mean by steam boiler?

A steam boiler is a steam generating heating system. This system creates energy by heating water to get steam. Industrial steam boilers are a heat exchanger that makes steam for external usage and has a combustion chamber and water vessel. The several varieties such as steam boiler industrial, electric steam boiler etc., contain those that are very trivial and those that are huge for more challenging jobs.

Steam boiler burns fuel to heat water. The arrangement of heat and water generates steam. There are three forms of heat used to produce steam: radiation, convection, and conduction.

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How a steam boiler works and its principles?

So firstly, let us discuss what is the working principle of boiler?
In a boiler, hot gases are generated by burning fuel in the furnace. These hot gases are made to come in contact with the water container where the heat transfer takes place between the water and the steam. As a result, the basic principle of the boiler is to convert water into steam by using heat energy.

Now we will discuss how exactly a steam boiler works?
The basic steam boiler working is extremely easy and simple to understand. The boiler is basically a closed vessel inside which water is deposited. Fuel (generally coal) is burnt in a furnace and hot gasses are generated.

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

Then this produced steam is piped to the turbine of the thermal power plant. There are several different varieties of boiler utilized for different purposes like sanitizing some area, running a production unit, sterilizing equipment, to warm up the surroundings etc.

Some basic information about the working parts: –

What type of pipe is used for boilers?
The pipes used in steam boilers are known as Boiler Tubes that are made from either carbon steel or alloy steel.

What is the maximum temperature of a steam boiler?
Generally 120°C., Sometimes up to 600°C.

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Main components of the steam boiler

The three main components of steam boiler are: –
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.

So what is economizer in boiler?
Economizers are basically known as heat exchangers that transfer the heat in the flue gas to another medium, usually the boiler feed-water, although other streams are occasionally used such as make-up water. There are two types of economizers: condensing and non-condensing.

What are the types of steam boilers?

Let’s try and understand what are the 3 types of boiler?

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.

What are steam boilers used for?

Some of the major application industries are as follows: –
Cement production: – Like other established industries, the cement industry is an extremely modest one. Investors and business vendors are always looking for legal ways to increase profit without decreasing the quality of the end-product or putting the lives of the end-consumers in danger. One of the ways to decrease the cost of production is by using every fuel used and decreasing the loss of energy. A waste heat recovery model is the solution and a waste heat boiler is the tool required to utilize the waste heat degenerate during cement production. The waste energy can be recycled, used to dry raw materials and complement the power supply. Industrial steam boilers can help generate up to 20% to 30% electrical power needed in cement manufacturing sites.

HVAC systems: – The use of steam boilers in HVAC systems include sanitation, water heating, cooking, waste energy utilization, and central heating. Industrial steam boilers are used to warm the air which is moved to the rooms of a house or warehouse.

Agriculture Sector: – Steam is utilized in soil sterilization. Soil steam sterilization is an agricultural process that involves the sterilization of soil with steam. Steam sterilization can be carried out in open fields or greenhouses. The procedure is effective in the partial killing of bacteria, weeds, viruses and fungi. The product of killing soil microorganisms is the release of cellular proteins, which increases the nutrients in the soil significantly. The procedure is considered as partial disinfection because spore-forming bacteria are heat-resistant and can survive or reactivate once the soil is back to its cold state. Industrial steam boiler used for Soil steaming is an ideal solution for soil fatigue. Revitalization, enhanced growth and disinfection are the benefits of soil steaming.

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.

Frequently Asked Questions

What is Non-IBR steam boiler?
NON-IBR Boiler is a boiler that is not covered under Indian Boiler Regulation. Any boiler, which is not covered under IBR i.e. a steam producing container whose volumetric capacity is less than 5 gallons (25 litres) is a Non-IBR Boiler & generates steam less than one kilogram per centimetre square design gauge pressure.

What is IBR steam boiler?
Steam boilers under IBR means any closed vessel beyond 22.75 litres in capacity and which is used expressively for producing steam under pressure and includes any mounting or other fitting attached to such container which is entirely or partly under pressure when the steam is shut off.

What is the difference between IBR and non-IBR pipe?
IBR Pipe falls under Indian Boiler Regulations. Boiler Pipe companies need to follow IBR rules (law of India) for manufacture, design, installation, and operation, the tubes which are not covered under Indian Boiler Regulation are NON-IBR Pipes.

What are the 2 types of boiler?
There are 2 basic types of boilers: firetube and watertube. The major difference between these boiler types is which side of the boiler tubes contain the combustion gases or the boiler water/steam.

What are the 2 types of steam?
Steam can exist in 2 forms: superheated or saturated.