How to select an industrial steam boiler?

Industrial steam boilers are used to transport heat energy from one location to another in your facility. The boiler is a pressure vessel that allows heat to be captured and efficiently carried from the boiler room to the point of use. However, due to the inherent dangers of a steam boiler operation there are strict rules and regulations for both the manufacturing and operation of these pieces of equipment.

To put it simply, boilers are internally fired heat exchangers to export steam or hot water. 

There are many variations when it comes to industrial steam boilers. Understanding the different types will help you determine which one meets your specific requirements.

In a firetube steam boiler, the hot gases from combustion flow through tubes to transfer heat into the water contained in the pressure vessel. Firetube boilers are often used at smaller industrial facilities with lower operating pressures. These types of boilers offer a cost-efficient and robust heating solution. Compared to a watertube steam boiler, a typical firetube boiler has a simple design, requiring minimal maintenance.

In a watertube steam boiler, the hot gases from combustion flow between the tubes filled with water. The original design circulates water in tubes heated externally by fire. These types of boilers operate at a larger capacity with the ability to handle greater pressures and higher temperatures compared to firetube boilers.

An electric steam boiler is driven by electrical energy. Unlike other boilers, industrial electric boilers do not transfer combustion energy.  Their design utilizes both the vertical and horizontal boiler shell orientation.  Electric steam boilers can be configured for both steam and hot water applications.  Next to extreme high turndown, zero emissions; another advantage is thermal shock resistivity. 

However at high capacity electric steam boilers require massive amounts of installed electric power.  Available power is today the restricting factor for this technology.  There is however a continuous push for innovation that may soon lead to a sustainable electric steam boiler that can provide steam or hot water at high capacities.

Condensing steam boilers are quickly becoming the go-to boilers in both industrial and residential markets. Due to the relatively low temperature of hot water loops in homes and small industrial applications, a condensing hot water boiler reaches efficiency levels (90% or higher) other standard boilers cannot achieve. Condensing steam boilers feature a specially designed heat exchanger that lowers the flue gas temperature enough to condense.  This condensation process generates extra energy that is captured and reused.

Other types of steam boilers can be complemented with a condensing economizer to also capture that condensation energy from the flue gas. However, given the difference between boiler water temperature and the boiler exhaust dew point, they can never internalize the condensing process inside the boiler design.

There are several factors to consider.  Obviously you start from the required output you need, the preferred efficiency levels.  Each proposal also has a specific investment cost.

In order to make the best decision, make sure to also considering the long-term impact of an industrial steam boiler on your operation. 

• How much steam is currently used by your facility?
• What output type is required of the boiler? (i.e. high pressure steam, low pressure steam, superheated steam, hydronic hot water, domestic hot water)
• What pressures and temperatures should the boiler operate at?
• What is the desired efficiency of the boiler?
• Which fuel will be used to fire the burner? (i.e. NG, oil, propane, biofuel)
• Where will the boiler be installed?
• Is the boiler easily accessible or hard to reach?
• Does the weather vary significantly throughout the year? (i.e. humidity, temperature, etc.)