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About Industrial Boilers

Industrial boilers are essentially tanks or vessels whose primary function is to efficiently transfer heat from combustion gases to water or steam through pipes, radiators, baseboards or convectors. Industrial boilers are produced by industrial boiler manufacturers and are much larger in size and capacity in comparison to residential units. The shapes of the vessels can be cylindrical or boxed with small tubes housing the liquid to be heated and/or converted into steam. The Industrial boilers produced by industrial boiler manufacturers are run by a fuel, such as natural gas, wood, coal, pulverized coal, wood or wood waste. Some industrial boilers use more than one type of fuel. Electrical units heat fluid with less chance of combustion, due to the lack of flammable fuel. Industrial boilers are typically constructed from cast iron and steel, but copper and stainless steel are also sometimes used. Most industrial boilers are housed in a fireproof, well-ventilated, stable-air environment within the building which they are heating.

Industrial boiler manufacturers create fire-tube and water-tube boilers as two basic designs. Fire-tube boilers work by forcing heat through tubes immersed in water. They are typically used in low-pressure applications. Water is circulated through tubes within the water-tube boiler enclosure. Hot flue gases are passed over the tubes, heating the water, and then discharged through a stack. Water-tube boilers are typically used in higher pressure applications, due to their greater structural integrity. Both designs are comparable in efficiency, but are not interchangeable because of structural considerations.

The efficiency of industrial boilers can be increased by combustion controls that automatically operate burners to match the steam or hot water demands on the industrial boilers. Economizers are optional energy-saving devices that can be fitted to existing industrial boilers. They are basically heat exchangers installed in the exhaust stack to preheat the boiler feedwater, transferring a portion of the heat in the stack gases to the water. Air preheaters also save energy by increasing the temperature of the mixture of fuel and air prior to combustion, allowing more availability of the heat resulting from combustion to heat water. Turbulators are twisted pieces of metal inserted into the tubes of fire-tube boilers that provide better heat transfer to the water by causing hot gases to travel more slowly and with more turbulence. Oxygen trim controls provide optimum efficiency by measuring the concentration of stack gas oxygen and automatically adjusting the inlet air at the burner.

Industrial boilers are often used as part of or with an industrial furnace. They are utilized to heat commercial buildings or pools. Industrial boilers are also used for purposes other than general heating. They can provide the hot water needed for water-based manufacturing processes such as papermaking. Industrial boilers can be used for direct injection processes as well. Mobile units are used in emergency relief and military situations that require hot water for showers or steam power for temporary energy.

Featured Articles

“More Back to Basics: Boilers”
http://web.newsguy.com/natclo/0210/caplan.htm

“Best Practices: The Engineering Approach for Industrial Boilers”
http://www1.eere.energy.gov/industry/bestpractices/pdfs/sd01art3.pdf

Images Provided by Unilux Advanced Manufacturing, LLC

Types of Industrial Boilers

• Boilers are machines used to generate hot water or steam.
  
• Cast iron boilers are modular boilers that are limited to low-pressure steam or hot water applications.
  
• Central boilers provide steam and heat for a larger complex heating system. Central boilers are often housed in a special environment with cooler temperatures surrounding them to prevent overheating.
  
• Double boilers allow for fine-tuned control and provide high thermal efficiency.
  
• Electric boilers are water or water/steam units powered by electricity rather than gas or other fuel.
  
• Firebox boilers use tube attachment techniques that are similar to those of the firetube boiler, but their combustion chambers are not round. Firebox boilers are compact, economical units that are typically used seasonally in low pressure steam or hot water applications in which efficiency is not a primary factor.
  
• Firetube boilers are cylindrical vessels with the flame in the furnace and the combustion gases inside the tubes. The furnace and tubes are within a larger vessel, which contains the water and steam.
  
• Flexible watertube boilers, also called “bent tube boilers,” are a common type of boiler valued for their resistance to thermal shock. Flexible watertube boilers are used in low pressure steam or hot water applications and can be a part of a field erectable package.
  
• Gas boilers use natural gas to heat the water and generate the steam necessary for heating applications.
  
• Hot water boilers are boilers whose primary purpose is the production of hot water.
  
• Membrane watertube boilers are compact boilers with high outputs that are used in high or low pressure or hot water applications. Membrane watertube boilers are ideal for applications in which space is limited.
  
• Mobile boilers are used often in temporary shelter environments, such as military camps or for emergency boiler breakdown situations. Mobile boilers can vary greatly in size and capacity and be towed to a location via semi-trucks or small vehicles.
  
• Packaged boilers are units that produce both heat and hot water to an environment.
  
• Steam boilers are boilers whose primary function is to produce steam. Steam boilers are a general type of boiler.
  
• Tubeless boilers are vertical boilers that have the burner located either at the bottom, middle or top. Tubeless boilers are easily operated boilers that have no tubes, but collect the steam over the water in a large jacket or “U” tube.
  
• Vertical boilers are commonly used in steam trucks, buses, trams and portable equipment, such as donkey engines utilized for sawmilling and dock work. The design of the vertical tube boiler lends itself to rough handling while in steam, making it ideal for use in situations in which the work plant has to be moved frequently over rough terrain.
  
• Waste-heat boilers make use of the rejected heat from other processes, such as gas turbines.
  
• Water tube boilers are safe boilers that consist of a header drum to which the water tube pipes connect. The drum and the tubes are usually surrounded by an insulating jacket or brickwork, and the fire and products of combustion are directed to pass through the tubes a multiple number of times, horizontally or vertically.