Are you feeling overwhelmed by the options available when it comes to boiler solutions for your home or business? Look no further! In this comprehensive guide, we will demystify the world of package boilers, helping you understand, choose types, components and application the most efficient solution for your needs.
For large industrial facilities, package boilers offer a compact and versatile boiler solution that is both reliable and cost-effective. In this article, we will explore the different types of package boilers, their functionalities, application, and their benefits. Understanding the intricacies of package boilers can be daunting, but CN BOILER breaks it down into easy-to-understand terms.
No matter your level of expertise, this guide is designed to empower you with the knowledge and confidence to make informed decisions for your boiler needs. Get ready to embark on a journey toward efficient heating solutions with our complete guide to demystifying package boilers.
What is a Package Boiler?
A package boiler, also known as a factory-built boiler, is a self-contained unit used to produce steam or hot water. It is a prefabricated boiler system that is built and assembled in a factory and then transported to the installation site for operation. These boilers are commonly used in a variety of industries such as food processing, chemicals, oil and gas, and pharmaceuticals.
Package boilers come in different sizes and capacities, from small electric heating units to large boilers that can produce high-pressure and high-temperature steam. They come in different configurations, including fire tube, water tube, and combination boilers. Each type has its own advantages and is suitable for different applications.
What are the Advantages of Package Boilers?
There are four main advantages to using a packaged boiler, including compact design, quick installation, cost effectiveness, and efficiency.
Compact Design: Packaged boilers are known for their compact design. All necessary components are integrated into a single unit, making them space-saving and suitable for installation in conditions where space is limited.
Quick Installation: The pre-packaged nature of these boilers allows for quick and straightforward installation. This is particularly beneficial for projects or situations where time is of the essence.
Cost Effectiveness: Packaged boilers offer cost advantages in terms of both initial investment and operational efficiency. They contribute to overall cost effectiveness by reducing installation time and lowering maintenance requirements.
Efficiency and Performance: These boilers are designed for optimal efficiency and performance. They are rigorously engineered to ensure reliable operation and continuous heat production.
What are the types of Package Boilers?
There are 3 main types of package boilers: fire tube package boilers, water tube boilers, and electric package boilers.
Fire tube package boilers:
These boilers have tubes inside the outer shell through which the hot gases pass. Heat transfer occurs through the tube walls, making them a common choice for small to medium-sized applications.
Water tube package boilers:
Water tube package boilers have tubes filled with water that circulates within the boiler. They are ideal for high pressure and high temperature applications and are used in a variety of industrial processes.
Electric package boilers:
Electric package boilers use electricity for heating. They are often selected for their clean, quiet operation and are suitable for indoor installations.
What Industries would Use Package Boilers？
Package boilers are widely used in a variety of industries due to their versatility and high efficiency. Some of the industries that commonly use package boilers include:
Manufacturing: Package boilers are used in manufacturing processes that require steam for heating or processing.
Healthcare: Hospitals and medical facilities use package boilers to generate steam for sterilization and other medical procedures.
Textiles: The textile industry uses package boilers for a variety of processes, including dyeing and drying.
Food Processing: Package boilers play a vital role in food processing applications, providing steam for cooking, sterilization, and other processes.
How are package boilers used in Food Industry ?
In the broad area of the food industry, the use of steam can be divided into many processes, such as:
Meat products:
Steam is used for mashing, filtering, pressure cooking, baking and hot smoking.
Hot water is used for boiling, stewing, cooking and steaming.
Hot oil is used for frying.
Dairy products:
Steam is used for pasteurization, whey production, high temperature processes, sterilization, thermalization and drying of milk powder.
Edible oil products:
Steam is used for drying and hardening.
Hot water is used for deodorization, bleaching, degumming, steaming and pressing/extraction.
Canned products:
Steam is used for pasteurization and sterilization of cans, containers and glass containers.
Hot water is used for boiling and cooking processes.
Sugar and starch products:
Steam is used for extraction, heating, evaporation and crystallization, often in combination with CHP systems (combined heat and power).
Confectionery products:
Steam is used for dehydration processes such as freeze drying and spray drying.
Steam is used for oven baking processes such as baking, tempering, grinding.
Steam is used for sugar block processing.
Snack products, pet food:
Steam is used for sterilization, preservation, extrusion and drying.
Hot water is used for boiling and cooking processes.
CIP system:
Factories also need steam for CIP system (cleaning in place) and cleaning processes.
What Are The Major Package Steam Boiler Components?
Steam boilers play an important role in many different industries, such as power generation and commercial hotels. Their main function is to produce steam from water, and while this may seem simple, there are many components in a steam boiler that perform this task effectively and efficiently.
The following are the main boiler components necessary for the proper functioning of a steam boiler
Burner: The burner, as the name implies, is used to burn fuel to produce heat. Fuel is injected from the fuel inlet, and air is mixed with the fuel inside the burner. The fuel is ignited, and the combustion reaction between the fuel and the oxygen in the air produces the heat required to convert water into steam.
Combustion Chamber: The combustion reaction takes place in a chamber called the combustion chamber. This chamber surrounds the burner and keeps the heat generated by the reaction inside the burner, protecting those outside from extreme temperatures.
Economizer: In a boiler, an economizer is a heat exchange device that heats a fluid (usually water) to the boiling point, but usually not beyond the boiling point of that fluid. Economizers can use the enthalpy in hot fluid streams that are hot but not hot enough to be used in the boiler, thereby recovering more useful enthalpy and increasing the efficiency of the boiler. They are a device installed on the boiler that saves energy by using the exhaust gases from the boiler to preheat the cold water used to fill the feed water.
Heat Exchanger: The heat exchanger acts as a heat transfer path between the burner and the water. This allows the water to be heated without direct contact with the burner and the fuel. This is because the combustion reaction releases some gases that mix with the water, making it difficult for the water to boil, and can even release some dangerous products by further reacting with the water.
Steam Lines: There are two main steam lines: the supply line and the return line. These pipes carry steam to different areas of the steam boiler system. Supply lines carry the steam produced by the boiler to the required area, for example, for making hot water in a hotel. On the other hand, return lines bring back the cooled steam, which can even turn back into liquid phase after losing the heat energy to the required area, and the cooled steam/water is heated again in the boiler.
Condensate pump: In a steam boiler, the condensate pump converts the steam into condensed water after the heat energy is utilized, pushes it to the required location, and helps it return to the boiler so that it can be reheated to produce steam.
Exhaust stack: The exhaust stack is used to remove the flue gas produced by the combustion reaction of air and fuel in the combustion chamber. The flue gas may contain dangerous gases such as nitrogen oxides and carbon monoxide, which can endanger workers and other personnel within the boiler facility. Therefore, these gases are exhausted from the steam boiler system through the exhaust stack.
Valves: Valves are used to allow or restrict the flow of fluids. Various valves are used in steam boilers. The return valve only allows the flow of fluids (in this case, steam and water) in one direction. The safety pressure valve is used to discharge excess gas/steam from the boiler system to reduce the pressure inside the boiler when the pressure exceeds the set value. If an emergency occurs, the stop valve stops the delivery of fuel to the burner.
Deaerator: The deaerator is used to remove dissolved gases from the boiler feed water. This is done to ensure that the water will not damage any surface inside the steam boiler system due to corrosion or other reasons when it contacts the surface.
Water treatment device: package boiler water treatment is to remove soluble salts from boiler water, with the focus on scale-forming ions such as sodium salts and calcium salts. Because these soluble salts have higher solubility as the water temperature increases. After reaching the dissolution equilibrium, crystals will precipitate, affecting the heat transfer efficiency of the boiler.
Conclusion
Whether you opt for gas, oil, or electric package boilers, the key to success lies in choosing the right type, ensuring proper use, and maintaining the system. If you have any further questions or need assistance with integrating package boilers into your operations, please today contact us at 86-13298311147 or heidyhan89@cnboilersolution.com.
