Wednesday, 19 July 2023 / Published in Boiler

Steam boiler systems are irreplaceable in the chemical process industries. Among various manufacturing and process industries, chemical industries are considered hazardous places to work due to their high probability of volatile components, the risk of explosions, and fires. Therefore, boiler safety is the highest priority in the chemical industry. Comprehensive examination and maintenance of the steam boiler ensure the safety of the process plant. Read the article to understand the importance of regular boiler assessment and maintenance in the chemical industries.

Understanding the role of steam boilers in the chemical industry:

Steam is extensively useful in chemical processing for various operations ranging from heating fluids to driving equipment. The steam boiler system that generates the steam from water comes in many different varieties and sizes. Let us look at the types and designs of steam boilers for chemical process plants, as well as issues related to their safety, reliability, and efficient operation.

Steam boilers depend on the combination of radiant and convective heat transfer, consisting of a furnace section and steam-containing parts. A lower mean temperature difference between the hot gas and the steam generally requires an increase in the surface of tubing and boiler weight. High-temperature boilers need special alloys like nickel-based for their hot section.

Designs of Boilers in the Chemical Industry:

Among various types of designs in steam boilers for the chemical industry, a commonly used configuration uses a steam drum. It involves the water entering the boiler through the economizer and passing to the steam drum. The water passes through the down comers to the lower inlet water-wall headers, rises through the water walls, and changes to steam due to the heat generated. The steam enters the steam drum and moves through multiple steam and water separators and dryers in the steam drum. It eliminates the water droplets from the steam and the cycle. Forcing the water into the steam boiler requires a special set of feedwater pumps.

Another variant is a basic design termed once-through boilers. The system does not include a steam drum. The water travels through the economizer, the furnace wall tubes, and the super heater section in a continuous pass without recirculation. A set of feedwater pumps supplies the required force for the flow through the steam boiler.

Safety and Reliability of Operations in the Chemical Industry:

Proper control and safety devices are very essential to ensure the safety and reliability of the process operations. Safety or relief valves are the primary safety feature on a steam boiler, preventing dangerous over-pressurization. Safety valves are required in case there are any failures of pressure controls or other devices controlling the firing rate.

The majority of boiler issues, failures, and accidents are preventable in the chemical industries. One of the most effective ways to avoid such problems is condition monitoring. Most boiler issues do not occur suddenly but develop gradually over a long period. The ideal way to detect important changes that may otherwise be neglected is to comprehensively record condition data and carefully evaluate those data periodically. 

Importance of Steam Boiler Maintenance:

Neglecting regular steam boiler maintenance can lead to serious issues. It is especially true in chemical processing plants, which pose a greater risk to the operating personnel due to the volatile substances they work with.

Ensuring regular inspection and maintenance plans ensure that the boiler is safe to operate. By following a schedule, any potential problems can be identified before it becomes a major issue. Safety should be the utmost concern, particularly while heating chemical reactors, which may result in serious harm to staff and damage to property.

The steam boiler maintenance is also necessary for efficiency. Neglecting steam boiler maintenance leads to increased expense due to reduced efficiency. If an issue is neglected during maintenance, it could lead to larger issues that impact the plant’s efficiency. A sudden downtime after a boiler failure can be extremely costly to the business.

Maintenance Checklist for Steam Boilers:

Regardless of a steam boiler type or design, it will always require regular maintenance. Below is a list of factors that should be examined during maintenance,

  • Boiler Construction and Design
  • Water Quality and Treatment
  • Ample Space for Emissions
  • Advanced Boiler Monitoring
  • Regular Inspections


Steam boilers have a crucial impact on the processing operations of chemical plants in terms of efficiency and productivity. Chemical industries require an ample amount of high-temperature steam for effective operations. Secondly, chemical industries tend to generate a large amount of emissions and waste heat. Therefore, it is essential to check that every requirement is met, before selecting a boiler manufacturer for a chemical plant.

Rakhoh Boilers manufactures highly efficient and reliable steam boilers preferred and trusted by various chemical process plants. Rakhoh’s Optipac and Waste Heat Recovery Boiler is an ideal choice for many chemical plants.

Wednesday, 19 October 2022 / Published in Steam Boiler, Steam Jackets
Steam Boiler Manufacturer In Maharashtra

Steam is integral to meet various process operational requirements in manufacturing facilities. High-quality steam is crucial for heating, drying, and sterilizing purposes in industries. Plant managers take several efforts to ensure that maximum heat is retained and utilized during the combustion process. Proper combustion requires an optimal amount of air, water, and fuels. However, waste or loss of heat hinders the steam generation process. It also leads to excess use of fuels that increase the costs. Therefore, steam boilers are installed with various accessories to ensure optimum heat. Steam jacket, also known as the jacketed vessel, is one such boiler accessory for heating and cooling purposes in the steam boiler.

What are Steam Jackets?

Steam jackets are designed in various ways to accomplish particular processing requirements. In other words, steam jackets act as a secondary enclosure over a boiler shell. A steam jacket consisting of an outer cylinder surrounding the vessel is the most commonly used jacketed vessel. The steam circulates on the outer jacket and condenses on the wall. Jacketed vessels contain an internal space or cavity usually filled with circulating fluid that is ideal for heating and cooling monitoring and to ensure minimal condensation on the outer jacket wall as well as the transfer of heat in the vessel.

For jacketed heating purposes, operating temperature is required to be up to 350°F. The steam and hot water generally serve as heat transfer forms. The advantages of using steam jackets are as follows,

The jacket temperature is controlled efficiently with hot water. It helps in preventing damage or loss to the product due to overheating.
Hot water enables the enhanced quality of the product
Hot water distributes heat more uniformly compared to steam. It destroys hot spots that lead to products baking on the walls of the vessel.
With glass-lined reactors, steam can shock and damage the lining. On the other hand, hot water facilitates hassle-free transitions from heating to cooling.

Steam jackets are excellent for heat transfer, easy to control, and efficient to maintain the high quality of the product processed. The heat transfer area or the vessel wall surface area is calculated by using the following formula,

Q = U x A x ΔTm

Although steam jackets are ideal for transferring heat, many process managers opt for hot water instead of steam to heat the jacketed vessels. The vessel walls are designed of stainless steel or glass-lined carbon steel, and the glass lining acts as an additional resistant layer for corrosion. The steam jacket space depends on the vessel size. But usually, its width ranges between 50mm and 300 mm.

Types of Steam Jackets:

There are three major types of steam jackets found,

Conventional steam jackets:

Conventional steam jackets provide excess coverage for the entire or part of the vessel. It is best suited for high-pressure applications by providing excellent insulation benefits and creating both inner and outer vessel walls. These jackets are available in baffled and unbaffled styles, along with agitating nozzles that aids in improving turbulence and overall efficiency in the absence of baffles.

Dimple steam jackets:

Dimple vessel jacket utilizes a light-gauge metal jacket adjoined to the main vessel through spots or plug welds. Such a system provides strength and durability with minimal excess weight or expense.

Half-pipe coil steam jacket:

Half-pipe coil vessel jackets are ideal for high-temperature processing operations in industries. These jackets are best suited for heat transfer and thermic fluid heating systems and are divided into multi-pass zones for maximum flexibility.

Heat transfer can greatly differ from one design to the other as well as from one processing application to the other. Usually, conventional steam jackets require more shell thickness to balance the stress of heat expansion, especially if the jacket and shell are manufactured from different materials. Dimpled steam jackets and half-pipe coil steam jackets are highly preferred for the thermic fluid heating system.

Applications of Steam Jackets:

The closed-loop heating system of the steam jacket fulfills the requirement of heating and cooling for a single process operation in industries. Vessels and equipment that require frequent cleanings also benefit from the jacketed vessel as it spares the equipment from internal coils for heating or cooling. Some of the industries that benefit from the ease and reliability of steam jackets are as follows,

  • Chemicals
  • Petrochemicals
  • Food
  • Milk and Diary
  • Distilleries and Breweries
  • Conclusion:

    Rakhoh Boilers are trusted steam boiler manufacturers in Pune for 38+ years, delivering efficient and reliable industrial boilers, waste heat recovery systems, thermic fluid heaters, and boiler accessories in over 26 countries worldwide. We provide excellent boiler services such as steam trap assessment, boiler automation, energy audit, annual maintenance contract, etc., to boost the efficiency and the productivity of the steam boilers.

    Explore more about our products and services on

    Monday, 17 October 2022 / Published in Boiler, Steam Boiler
    Optipac Boiler

    Steam boilers are vital equipment for steam generation in the process and manufacturing industries. Therefore, it is critical to know when it is time to replace an industrial boiler system. However, it is usually observed that facility managers wait for a steam boiler to break down entirely before replacing the unit. However, upgrading the steam boiler process plants can save a significant amount of money annually while also benefiting from increased efficiency and improved steam production when the boiler operates. Rakhoh Boilers being a trusted name as a boiler manufacturer in India has listed down some of the important signs that indicate the replacement of the steam boiler system.

    Outdated Boiler System:

    First and foremost, it is important to consider the lifespan of the steam boiler. If the boiler is older than 10-15 years, it is ideal to start looking for a replacement. It is true even if the boiler does not display any major faults. As the technology has advanced significantly in recent years, the old models are incapable of comparing with the efficiency levels, safety features, and smart control options of the latest steam boilers.

    Frequent Breakdowns:

    If there are occurrences of any type of boiler issues every week or topping up of the pressure, it indicates that things are about to change for the worst. The expenditure of the new parts, call-outs, and quick reparations can be spent much better on a replacement boiler that is efficient and reliable.

    Boiler System Emits A Noise:

    Sometimes, steam boilers are so outdated that the noises emitted from them are considered normal. On the contrary, the banging, gurgling, and kettling noises heard from the steam boiler indicate a boiler issue. If neglected, it can lead to severe damage in the process plant and breakdown over time.

    Yellow-Colored Flame:

    A steam boiler functioning properly ensures complete combustion with a blue flame. But, if the boiler flame is yellow, it means that there is a risk of carbon monoxide emission, which is a serious issue. It is a hazardous, odorless, and colorless gas that can prove to be fatal if exposure levels are overly high. The symptoms of carbon monoxide poisoning consist of dizziness, nausea, headaches, and fatigue.

    Water Leakages:

    If there are any water leakages in the steam boiler system, it can result in significant damage to other steam boiler components. Therefore, it is important to contact an engineer as soon as possible before things escalate and become dangerous.

    Replacement Parts Difficult to Find:

    If process plants find it difficult to procure the parts of the steam boiler for replacement, it is to be concluded that the system is outdated. It is a quite clear warning sign that the boiler’s days are limited, and replacement of the boiler is the need of the hour.

    High Stack Temperature:

    If the steam boiler faces unusually high stack temperatures, it is an indication of unsafe conditions and poor heat transfer. It may be caused due to poor water management, poor combustion, or low water level.

    Poor Combustion:

    Improper or insufficient airflow and fuel flow can lead to significantly noticeable pulsations and surges.

    Reduction in Efficiency:

    If the steam boiler system takes too long to operate or to generate steam, it showcases the inefficiency of the boiler system. In such situations, it is imperative to contact the boiler manufacturer for their expert guidance in replacing the system.

    What is better– Replacement or Retrofitting?

    Even if the steam boiler displays no decline in condition or performance, operations managers need to consider whether they should opt for a boiler replacement or retrofit. A boiler retrofit can offer the advantage of increasing the efficiency between 10% and 12%. On the other hand, a complete steam boiler replacement may offer even greater percentages depending on the boiler.

    In either case, a retrofit boiler or a complete boiler replacement significantly reduces the future expenses of the process plant. Considering the average boiler consumes up to four times its original value in energy costs per year, it is easy to see how efficiency savings can quickly add up.


    Rakhoh Boilers is one of the trusted boiler manufacturers in Pune since 1983. With 38+ years of experience and expertise in thermal solutions, we deliver highly efficient and reliable industrial steam boilers, waste heat recovery systems, thermic fluid heaters, and boiler accessories to over 20 process industries in 26 countries worldwide. We provide excellent boiler services to boost the efficiency and productivity of the boilers.

    Visit for more details on our products and services

    Saturday, 15 October 2022 / Published in Boiler, Steam Boiler
    huskon bolier

    Most manufacturing industries require steam boilers for accomplishing process operations. Steam is integral for various purposes of heating, drying, processing, sterilizing, etc. The textile industry is one such example that requires steam for its major processing stages. Textile is one of the ancient industries that have witnessed various changes and advancements over the centuries in terms of its processing. Several stages convert the raw fabric into a finished garment. Let us have a look at it in detail,

    Yarn Manufacturing or Spinning:

    The raw material or fiber and man-made fibers like synthetic or nylon are transported for yarn manufacturing. In this textile process stage, raw materials are converted into yarn for knitting, weaving, or crocheting. The raw materials are sorted and cleaned for creating the final yarn or thread.

    Fabric Manufacturing or Weaving:

    The next stage of fabric manufacturing involves transporting yarn from one machine to another in order to create a length of fabric.

    Wet Processing:

    The fabric wet processing operation includes dyeing and finishing of the fabric. The dyeing process introduces colors to the fabric, while the finishing process adds chemical properties such as anti-pill, soil release, flame retardant, etc., to enhance the fabric quality. The printing process includes inkjet printing on fabrics.

    Garment Processing and Finishing:

    The final process in the textile industry includes designing and sewing the final garments. It is followed by spot removal, ironing, and finishing before transporting it to markets.

    Role of Steam Boilers in Textile Processing:

    Steam boilers are indispensable in textile processing as the major process operations depend on steam or hot water generated from boilers. Textile processing units consider every factor before selecting a steam boiler that meets their demands effectively. Here are the primary stages of the textile process that requires steam or hot water,


    The pre-treatment phase is one of the important stages in the textile process that involves the removal of dirt or impurities from the fabric before the dyeing and printing process. The pre-treatment stage requires efficient steam boilers to produce clean and pure steam or hot water.


    The dyeing stage involves adding pigments or dyes to fabric to color them. Although the dyeing process can occur at any stage, it primarily occurs after the yarn manufacturing or fabric manufacturing stage of the textile process. The transfer of dye to the fabric requires a precise amount of moisture and heat provided by steam. Steam boiler enables the heating of water and steam at the determined temperature that is required to dye the fabric in exact color.


    The printing stage in the textile process is similar to dyeing except that printing includes patterns or designs to the fabric, whereas dyeing includes uniform coloring. Depending on the type of fabric, the printing stage uses several methods. Steam boilers are essential for providing the precise amount of heat and moisture required for the printing process.


    The finishing stage of the textile process involves several steps. It includes the removal of wrinkles from fabric. A steam boiler is vital for providing steam for the ironing purposes that provides excellent finishing.

    Factors to Consider while Choosing Steam Boiler for Textile Process:

    Deciding a steam boiler for the textile process is imperative to ensure optimal efficiency and productivity. Managers in textile processing units consider the following factors before determining their choice of steam boiler,

    Seamless with Fluctuating Demand:

    The steam requirements in textile process operations are fluctuating and require robust steam boilers that can effectively handle the changing demands. In such situations, steam boilers with a quick start or shut-off are best-suited for processing. Comparatively, water tube boilers perform better than fire tube boilers with the fluctuating load.

    Fuel Efficiency:

    Due to fluctuating demand for steam, the textile process faces the difficulty of fuel wastage that leads to excess costs. Therefore, the steam boiler must perform effectively and ensure complete combustion to ensure optimal utilization of fuel.

    Easy Maintenance:
    Steam boilers in the textile process operate throughout the day and hence require regular maintenance for enhanced results. Negligence of boiler maintenance may cause boiler failure, resultantly shutting the textile process operations and leading to significant losses.

    Calculating the Capacity and Heating Parameters of Steam Boilers:

    The capacity of a steam boiler depends on the heating load that includes heat losses in boiler tubes and pipes. Additionally, the heating parameters like temperature and pressure must be determined.


    With 38+ years of experience and expertise in thermal solutions, Rakhoh Boilers are the leading boiler manufacturer in India and overseas, with more than 3000 boiler installations in over 26 countries globally. Our Combo X model is the preferred steam boiler model in the textile industry. We have delivered our efficient steam boilers in over 360 textile process and dyeing units. Catering to 20 process industries worldwide, we manufacture steam boilers, waste heat recovery boilers, thermic fluid heaters, and boiler accessories. We offer the best boiler services like boiler automation, steam trap assessment, energy audit, annual boiler maintenance, etc to ensure hassle-free operations of steam boilers.

    Visit to know more about our products and services.