Greener Upgrades blog series #6
Finding the right steam boiler
When assessing the requirements for a steam boiler, it is crucial to gather comprehensive information to ensure the system meets the specific needs of the site. Here are some important factors to consider.
The type of process on site
Different processes have different requirements for steam quality and quantity. Understanding the application helps tailor the boiler system to meet these needs effectively. There may be special requirements; for instance, if steam is encountering food, we would need to use food-grade oil in our system. Our boilers are designed to accommodate such specific needs, ensuring compliance with industry standards and maintaining process integrity.
Our containerised steam boiler house includes a steam boiler, chemical treatment, blowdown tank, and water softener all built into one container, to ensure compatibility for a wide range of needs.
The type and quantity of steam required
At Aggreko we use the ‘from and at 100 ºC’ rating to measure energy output rather than steam production. For instance, a boiler with a 5000 kg/hr rating generates sufficient energy to transform 5000 kg of water at 100 ºC into 5000 kg of steam within one hour. Knowing the type (saturated or superheated) and quantity of steam ensures the boiler solution is tailored to your application. Supplying the wrong type of equipment without the right ancillaries would cause serious system issues like process malfunctions, insufficient steam supply, or energy wastage. Incorrect steam type or quantity can result in energy inefficiency, increased operational costs, and potential damage to equipment or products. Our systems provide rapid steam production, with steam produced in as little as 3 minutes ensuring you have the steam you need quickly and efficiently. The steam is also high quality, producing 99.5% dry saturated at all loads.
Energy efficiency
Steam generation can be a costly and a fuel intensive operation. It's important to consider the energy efficiency of the steam boiler. Our boilers have a high boiler house and combustion efficiency and can be stood down and started back up quickly without manual intervention to conserve energy, leading to fuel savings of 20-25% in start stop applications.
The operating pressure of the system
Determining the pressure range (e.g. low pressure, high pressure) needed for your processes is essential. The operating pressure affects the design and safety features of the boiler and may necessitate additional ancillaries, such as a low-pressure valve. Ensuring the correct pressure range is crucial for operational efficiency and safety. Operating at the wrong pressure can cause safety hazards, reduced efficiency, and potential damage to the boiler and downstream equipment, leading to costly repairs and downtime.
Our boilers have a low water volume design (around 10 times less than fire tube boilers), ensuring high levels of safety and efficiency, adapting seamlessly to the required pressure ranges.
Our boilers have a low water volume design (around 10 times less than fire tube boilers), ensuring high levels of safety and efficiency, adapting seamlessly to the required pressure ranges.
Stable or variable demand?
Having an accurate profile of the steam demand helps determine the required capacity and enables us to understand the boiler's requirements. Some boiler types respond better to fluctuations in demand, while others prefer a constant steam requirement. Understanding demand patterns helps ensure the control systems can handle fluctuations without compromising efficiency or reliability. Failure to account for demand variability can lead to oversized or undersized boilers, resulting in inefficiencies, increased fuel consumption, and higher operational costs. Our systems can adapt to changes in steam demand with a fast response, optimising steam output to match the site's varying load.
The type of fuel available on site
Assessment of available fuel sources (e.g. natural gas, oil, biomass) is essential to ensure compatibility with the boiler system. There may be environmental regulations that need to be complied with, making the right boiler choice crucial. For example, our boilers can use HVO to meet stringent NOx standards. The wrong type of fuel can lead to increased emissions and high fuel costs.
Our dual fuel burner option allows for the use of gas/diesel or HVO, minimising the carbon footprint and ensuring compliance with environmental standards.
Our dual fuel burner option allows for the use of gas/diesel or HVO, minimising the carbon footprint and ensuring compliance with environmental standards.
Steam condensates
By recovering condensates, water and energy consumption is reduced, leading to lower running costs and enhanced project sustainability. It is also important to know the temperature of the condensates to ensure the return system is compatible. Getting the condensate temperature wrong can cause thermal shock or damage within the system, leading to downtime and costly repairs. Specifying connection types helps pre-plan the installation requirements.
Our systems feature minimal interconnecting pipework, simplifying and speeding up installation and commissioning, while maintaining efficient and safe transport of steam, water, and condensates.
Our systems feature minimal interconnecting pipework, simplifying and speeding up installation and commissioning, while maintaining efficient and safe transport of steam, water, and condensates.
Piping distance for steam, supply water, and condensates
Gathering information about piping distances ensures correct sizing of pipes and pumps, reducing pressure drops and energy losses, and ensuring efficient and safe transport of steam, water, and condensates. Incorrect sizing can lead to an inadequate steam supply, resulting in production loss and system failures.
The laydown area
The laydown area must be a flat, level surface for the boiler. Appropriate clearance must be provided for safe maintenance and servicing. Consideration for future expansion is also crucial. If more capacity may be required, space for an additional boiler should be accounted for. Inadequate space could be dangerous and complicate maintenance and setup. Our containerised systems can safely be placed side by side, provided there is access to the container doors for servicing and maintenance. Our 10ft or 20ft high cube containers offer a compact, condensed footprint, ideal for projects where space is at a premium. They allow boilers to be placed side by side with easy access for maintenance.
The exhaust/chimney size
If the boiler is close to where people are working or other equipment, an extended exhaust/chimney may be required. Specific regulations regarding chimney height must be understood to avoid non-compliance and potential damage to nearby workers or equipment due to lack of ventilation.
What type of boiler best suits the project?
Considering the above factors helps determine the most suitable boiler type. For a detailed comparison, see our blog on fire tube vs. Aggreko boiler systems.
By addressing these questions, you ensure that the steam boiler system is appropriately sized, efficient, and reliable, ultimately leading to optimised performance and cost savings while meeting regulatory and safety standards. These consequences highlight the importance of gathering accurate and comprehensive information when planning a steam boiler system.
By addressing these questions, you ensure that the steam boiler system is appropriately sized, efficient, and reliable, ultimately leading to optimised performance and cost savings while meeting regulatory and safety standards. These consequences highlight the importance of gathering accurate and comprehensive information when planning a steam boiler system.