10 Key Considerations for Choosing a Good steam Boiler?

The Industrial Steam boiler is a vital and integral piece of equipment for various industries and businesses. Steam boiler selection is an important step that helps in the optimisation of the overall Industry. Hence, choosing a Good Steam Boiler is Important. However, one should first understand about boiler and their work. What is a Steam Boiler, and How does it work? A steam boiler is a pressurized system that generates and collects steam used for heating and energy sources in Industries and commercial businesses.

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A steam boiler has a container, heating source and a valve to process water to steam using a heat source. However, Industrial boilers are different from Domestic boilers as the Industrial heating systems have different temperature and pressure outputs suitable to heat Large commercial properties. There are many Industrial Steam Boilers, but the Most Commonly used are firetube boilers and water tube boilers. Firetube Boilers are Low-pressure boilers known for their easy operation and small steam capacity. They offer a cost-effective solution with a simple design and minimal maintenance. However, Water tube boilers are high-pressure boilers that operate at high power and temperature.

After the determination of Boiler type/Design needed, businesses should consider the following aspects to choose a suitable steam Boiler:

1) Safety:

Safety is the foremost and essential factor to consider while choosing a Steam boiler. As steam boilers with high or low pressures can be dangerous, one needs to be cautious while handling them. Hence, while selecting the required steam boiler, look for its safety system. A boiler with a low water content design makes the catastrophic explosion impossible.

2) Cost:

Calculating the Cost of the boiler for the long term purpose is also essential. One should not purchase a cheap boiler and then spend more on their repair and maintenance later on. Although Price is important, consider the overall cost of operation while choosing a Steam Boiler. Different factors such as rated capacity, pressure, temperature, fuel type, and run hours are crucial to select an efficient boiler. As Cost and efficiency go hand in hand, we should give these specifications of Boiler’s Performance attention.

3) Reliability:

For a smooth business run, a steam boiler should run smoothly as well. The reliability and durability of the boiler system is another important factor. High mass boilers have thick metal used in the manufacturing of pressure vessels, leading to an increase in the boiler’s durability. Hence, industrialists should choose reliable machinery with a long lifespan.

4)Fuel Sources:

The type of fuel needed to generate heat should consider knowing the resources available with the Industrialist. Steam boilers system uses coal, natural gas, biomass, and other energy to generate heat. Such Coal boilers are pretty costly with High emissions, whereas Biomass boilers are most economical and cheaply and readily available.

5) Ease of Maintenance:

One needs to consider the period of maintenance a boiler needs to work efficiently for an extended period. A well-maintained boiler system involves suitable pressure vessels, water treatment, Tanks, and reverse osmosis systems. Hence, Look for an effective monitoring and control Boiler system with a support plan for routine maintenance issues. And Govern their upkeep and maintenance from time to time for smooth functioning.

6) Size:

The less space a boiler occupies, the better. A boiler with a low footprint is better for both space and money. Industrialists should take proper measurements before Purchasing any steam boiler. Also, they should consider the space required for maintenance as well in the overall Footprint.

7) Steam Boiler Emission:

Due to the increase in air pollution, the atmospheric gas emission limit is an essential factor to consider. Earlier, there were limits on the region of provenance. One must choose a steam boiler to reduce harmful emissions of gases according to Thai laws & regulations.

8) Combustion Technology:

One should look for a High turndown level while maintaining good combustion efficiency. A boiler’s Thermal and combustion efficiency is essential for the burner’s performance. Industrial Boilers burns coal, biomass and fluids using different combustion Technologies such as low NOx burner. Here, effective turndown measures the lowest level of fuel input and air adjustment for good combustion efficiency.

9) Start-Up Time:

Time is Money! One needs steam in a narrow time frame. Water-tube boilers are such boilers that require less startup time and convert water into steam in a short period. Hence one should consider boilers with 5 to 20 minutes of startup time for efficient usage.

Boilers are considered central heating systems because the heat generated by the equipment is spread throughout the home. However, unlike other heating methods, there is typically a small lag time between the boiler turning on and the heat being dispersed.

Most boilers produce steam or hot water using natural gas or heating oil, and are either condensing or non-condensing (see below). Boilers are required by the federal government to be at least 80 percent efficient, and can have efficiencies as high as 98.5 percent. Some boilers can be expensive to install, but all types typically last 15 to 30 years, and you can avoid possible repair headaches by reading our guide to the Most and Least Reliable Boilers. You should also look at Consumer Reports’ and surveys of 2,137 boilers, owned by members who installed a new unit between and , to get a clearer picture of which brands are preferred by members.

Gas-Fired Boilers
Gas-fired boilers are fueled by either natural gas or propane, and are highly efficient. However, natural gas is not available everywhere, and some homeowners at the end of a gas pipeline pay higher fuel prices. Propane typically is more expensive than natural gas, but it’s available throughout the U.S.

Oil-Fired Boilers
If you buy a oil-fired boiler, you’ll need heating oil delivered and stored in tanks like the one above, and your operating costs will be affected by the rise and fall of oil prices.

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Some boiler manufacturers now offer models that use biodiesel fuel, which produces less pollution than regular heating oil. Depending on oil prices, biodiesel heating oil can be cost-competitive with standard oil. However, because it burns cleaner and lubricates the system, biodiesel fuel can reduce your boiler service and cleaning costs.

Electric Boilers
Electric boilers are highly energy efficient. However, they typically are not economical because electricity costs more than other fuel types in many parts of the country. If you are interested in electric heating, consider a heat pump.  

Steam Radiators
Steam heating is one of the oldest heating technologies, and upright metal steam radiators positioned along walls in older homes are common. They can provide consistent, comfortable heat.

Steam radiators need some simple maintenance to work properly and efficiently. In addition, a radiator can warp or create a groove in the floor. If that happens, the radiator may tilt, causing it to make loud banging noises. Plus, steam radiators on exterior walls can radiate some heat to the outdoors, and limit your ability to position furniture around the room.

Hot Water Radiators
More common in newer homes, hot water radiators run along a room’s baseboard or stand upright like a steam radiator. Hot water radiators can reduce your home’s energy consumption because they allow you to control the temperature of each floor or a large space. A heating professional can install automatic valves on the radiators, and connect them to separate thermostats.

The most common problem with hot water radiators is unwanted air in the system. Plus, like steam models, upright hot water radiators can limit your ability to position furniture.

Hydronic Radiant Floor Heating
Hydronic (water) systems are the most common radiant floor heating systems. A boiler heats water and flows it to tubing under the flooring, which acts as a giant radiator. Hydronic systems can heat a whole house, but they’re mainly used to heat a single room or area, and some can be zoned so thermostats regulate each space.

Hydronic radiant heating is more efficient than baseboard heating and usually more efficient than forced-air heating, too. It also doesn’t distribute allergens like forced-air systems can, and uses little electricity. However, hydronic systems can be expensive to install and to repair, and may not be as efficient if the floor is covered with thick carpeting.

Condensing vs. Non-Condensing
All boilers are either condensing or non-condensing. A condensing boiler concentrates water vapor produced in the heating process, and uses waste heat to preheat cold water entering the boiler. Condensing boilers are extremely energy efficient because they can provide ample heat while operating at lower temperatures.

Non-condensing boilers typically operate at higher temperatures, and some heat ends up being vented outside. Non-condensing boilers are 80 percent to 88 percent efficient, while condensing boilers have efficiencies greater than 88 percent.

Sealed Combustion vs. Non-Sealed Combustion
Boilers are either sealed-combustion or non-sealed combustion units. You should buy one that is sealed combustion because it brings outside air into the burner and directs exhaust gases outside. Non-sealed combustion boilers draw heated air in and then send it up the chimney, wasting the energy used to heat the air. Also, sealed-combustion boilers won’t introduce dangerous gases into your home.

Climate
If you live you in a cold climate, a boiler may be a good choice for your home. But if you live in a warm climate, you may not need a central heating system. In that case, consider a heat pump, which can satisfy your air conditioning needs as well as moderate heating requirements.

Fuel Type
Gas-fueled boilers may cost less to operate than oil-fueled ones if heating oil prices are high. However, the fuel type you choose will depend on what’s available in your area.

Sizing
The boiler’s size is as important as its efficiency. If the boiler is undersized, it won’t work efficiently; if it is oversized, it will cost you more to heat your home. Work with a heating and cooling professional, who should use an Air Conditioning Contractors of America (ACCA) Manual J calculation to determine the right boiler type and size. The calculation will take into consideration your home’s foundation, wall thicknesses, insulation values, windows, air filtration and more.

Cooling
Boilers only provide heat; so you’ll need a cooling system, too, if you want to air condition your home.

Boilers are rated with an annual fuel-utilization-efficiency (AFUE) score, which tells you how much energy is being converted into useable heat. New boilers must have an AFUE rating of at last 80 percent, and high-efficiency models are 90 to 98.5 percent efficient. The higher the rating, the higher the equipment cost, but the lower the operating cost.

For example, say your current boiler’s AFUE score is 65 percent and you pay $1,300 a year for fuel bills. If you install a high-efficiency natural gas system with an AFUE of 90 percent, your total yearly savings should be about $364.

Unless it’s an emergency, and your current boiler is no longer functioning, don’t buy a new boiler until you make the rest of your home as energy efficient as possible, because reducing your home’s heating load will allow you to buy a smaller, less expensive system. If needed, you should:

• Add insulation to your attic and walls.
• Add weather stripping around doors and caulk around windows to keep heat from escaping.
• Properly insulate cooling system ducts in crawl spaces and attics.
• Clean your chimney.
• Set your ceiling fans to spin clockwise to blow rising heat down.
• Install and set programmable thermostats to automatically lower the temperature at night and while you are away. Programmable thermostats can save you 10 percent annually on your heating bills.

Boilers should be serviced annually by a heating professional to ensure efficient heating. The technician should:

Hot Water Boilers
• Test the pressure-relief valve and high-limit control.
• Inspect the pressure tank.
• Clean the heat exchanger.

Steam Boilers
• Drain some water to remove sediments.
• Check the safety controls.
• Analyze the water and add chemicals if needed.
• Clean the heat exchanger.

Both Systems
• Check the vent connection pipe and chimney to see if they are deteriorating.
• Check the heat exchangers and pipes to see if they are leaking.
• Adjust the water and air temperature settings for optimum efficiency and comfort.

Upright and Baseboard Radiators
• Make sure radiators are not obstructed by furniture, carpeting, rugs, and drapes.
• Be sure to release trapped air from hot water radiators at the beginning of the heating season and possibly one more time during the heating season. If you are unsure how to perform this task, contact a heating professional.
• Place shims under the radiators so they are pitched slightly toward the pipe in a one-pipe system or toward the steam trap in a two-pipe system.
• Place heat-resistant reflectors between radiators and exterior walls to keep heat from escaping.

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