Steam boilers are imperative for the operation of the process and manufacturing industries. Steam is vital for heating and processing purposes in industries, and therefore, a steam boiler consists of various components that ensure the steam generation takes place seamlessly. One such component in the boiler system is a heat exchanger. Heat exchangers are long tubes of metal with openings at both ends. It enables the heat transfer from the gas in the burners that produce toxic byproducts when it burns. Heat exchangers are not coils but are usually made from steel sheet metal and enable the gas-to-air exchange.
Importance of Heat Exchangers in Steam Boilers:
In a boiler system, the hot-water radiators harness heat from hot gas jets, but initially, the water needs to absorb the heat energy from the gas. The heat exchanger safely allows the passing of heat energy from gas to the water. If water is heated directly from the gas, the flames would be extinguished by the water. The basic principle of the heat exchanger is that it allows the transferring of the heat without transferring the fluid (liquid or gas) carrying the heat. The surfaces through which heat passes are called heat transfer surfaces. Heat transfer takes place in the steam boiler, where hot gasses from the combustion of fuel transfer levels of intense heat through the steam boiler tubes to produce steam.
The build-up of any hindering material such as scale, corrosion products, or micro-organisms on heat transfer surfaces slows down the heat exchange.
Indications of Issues in Heat Exchangers:
Several indicators point towards issues in heat exchangers and require prompt actions. Some of them are as follows,
Black soot around the furnace is a clear sign that the gas is not burning properly. Unhealthy and incomplete combustion leads to dirty soot around the furnace. It usually leads to a damaged heat exchanger or an issue with the burner or furnace flame.
Although gasses such as carbon monoxide are odorless, any strange or unpleasant odor near the furnace or air ducts requires professional attention. Cracked heat exchangers can leak combustion gasses into the boiler system that can cause a clear and present odor. In such situations, it is crucial to immediately turn off the heating system and seek professional help to diagnose the situation.
Water Surrounding the Furnace:
If water is found on the floor near the furnace, it may indicate a problem with the heat exchanger. Whether it is condensation or a cracked heat exchanger, seek professional help right away to determine the cause.
If there are complaints of other aging problems with the furnace, such as wear and tear, loud noises, it is ideal to have a professional diagnose the entire steam boiler system.
How to Increase the Efficiency of the Heat Exchanger in Steam Boiler?
The ideal method to reduce the operating expenses in a process plant is by using and maintaining energy-efficient equipment
Reduce carry-over to avoid impurities and ensure proper levels of BTU content at end-use.
Impact of poor heat transfer in the steam boiler:
Rakhoh Boilers are one of the leading manufacturers of industrial steam boilers in Pune since 1983. Over 38+ years, Rakhoh has successfully installed more than 3000 boilers in 26 countries worldwide. We also provide excellent boiler services like energy audit, boiler automation, steam trap assessment, annual boiler maintenance, fuel conversion, etc.
For more details on our products and services, visit www.rakhoh.com