Steam Boilers are the heart and soul of the process and manufacturing industries globally. Boiler manufacturers are working consistently with their research and development department for advancement in thermal engineering by introducing steam boilers with enhanced design, offering efficient and sustainable performance. With the emergence of reputed boiler manufacturers, process industries consider every factor before deciding on a steam boiler for their facility. Rakhoh Boilers, as a leading boiler manufacturer in India, ensures to deliver excellent steam boilers to their clients that are efficient and reliable in process operations. As a staunch supporter of advancement in thermal solutions, Rakhoh boilers have listed some important factors that process plant managers must consider before choosing a steam boiler.

Importance of Steam Boiler Selection:

Steam boiler selection plays a crucial role in increasing the overall efficiency of a processing plant. When choosing an industrial steam boiler, it is necessary to consider the specific requirements of the process operation. Compared to the fuel cost, the initial capital cost on the steam boiler is merely 15 % or less in the life span of the steam boiler.

The two most commonly used boiler types in process plants are firetube boilers and water tube boilers. Although firetube boilers are less expensive and operate easily, it includes a relatively small steam capacity. On the other hand, water tube boilers efficiently produce high-pressure steam and are usually preferred in applications requiring higher capacity.

However, other considerations should be accounted for while selecting the appropriate steam boiler and boiler manufacturer for your process plant requirements. These factors include:

• Boiler Design / Type:

Firetube boilers and water tube boilers are the two primary types of steam boilers used in process plants. Firetube boilers pass hot gas from a heat source through tubes placed in a water-filled shell that converts the water into steam. Firetube boilers require a low capital cost and are usually easily operated. However, they come with relatively small steam capacities.

On the other hand, water tube boilers pass water through the tubes heated by hot gases in the boiler shell. Although it consists of higher thermal efficiency as compared to firetube boilers, it is more expensive. Water tube boilers are generally used to produce high-pressure steam and are majorly found in applications requiring high capacities.

• Fuel/Heat Source:

The fuel type for generating heat is also an important factor to consider for selecting a steam boiler. Some of the primary fuel types used in steam boilers include:

Coal: 

Coal-fired boilers are usually known for higher emissions, requiring expensive scrubbers and electrostatic precipitators for the removal of harmful gases and fly ash from flue gas.

Natural gas: 

Gas-fired boilers are ideal for natural gas fuel that is cleaner than other energy sources, is highly combustible, and has a high energy-to-heat ratio. It also ensures relative safety for storage purposes and provides certain environmental benefits over other fuel sources.

Biomass: 

Biomass-fired boilers are used primarily in the sugar, paper, and distillery industries as it uses the by-products of the operational processes as fuel and is significantly economical in process plants with biomass fuel available readily and cost-effectively.

• Proper Combustion:

Steam boilers offering combustion with coal, biomass, or petrochemical fuel uses different combustion technologies. For example, stoker uniformly spreads the coal through the burner on a moving grate. On the other hand, fluidized bed technology includes air bubbles through a bed of pulverized coal or biomass that provides oxygen for combustion. These technologies impact thermal efficiency. Therefore, steam boiler selection should consider proper combustion along with the capital and operating costs.

• Safety:

High pressures and temperatures can contribute to hazardous accidents in steam boilers. It is also advisable by boiler manufacturers to approach and operate low-pressure steam boilers with caution. While selecting a steam boiler, decide on the safest option that meets the requirements of the process plants. It is also vital to understand the maintenance required for the safe operation of the chosen steam boiler.

• Reliability:

Reliability is one of the most crucial factors as the process operations depend tremendously on a steam boiler. It is important to assess the water quality as it has a significant impact on the performance of the steam boiler. Water softeners, demineralizers, or reverse osmosis systems are the best methods to improve feed water quality.

• Cost:

It is natural for the process plants to consider the cost of the steam boiler as a priority of their purchase criteria. Although cost is important, while considering variables like run hours and fuel costs, it is challenging to know the precise cost of the steam boiler. Simply put, a cheap boiler is likely to cost more expenses down the road.

• Life Span Expenses:

Calculating and assessing the expenses of life span economics is an important consideration. Finding the minimal life cycle cost includes factors, such as initial cost, operating schedules, estimated steam boiler life, overall boiler efficiency, warranty, annual operating expenses for parts, and blowdown requirements.

• Performance of Steam Boilers:

Steam boiler applications may require additional performance with heat or pressure that is lost at a significant expense if the steam boiler fails. High-performance steam boilers provide consistent and dependable operation for these applications.

About Rakhoh Boilers:

Rakhoh Boilers has been a trusted boiler manufacturer since 1983, delivering a range of efficient and reliable steam boilers, waste heat recovery systems, thermic fluid heaters, and boiler accessories. We provide excellent boiler services to ensure optimal efficiency and productivity of the steam boilers to your clientele, spread over 26 countries worldwide.

For more information on our products and services, visit www.rakhoh.com