In the realm of industrial operations, high-efficiency boilers play a pivotal role in meeting energy demands and enhancing productivity across diverse sectors. This article discusses 30 frequently asked questions about high-efficiency boilers in China, covering excellent boiler manufacturers in China, as well as boiler types, working principles, usage precautions, maintenance, etc., and is suitable for finding high-efficiency boilers or boiler suppliers in China.
In this comprehensive guide, we will explore 30 key questions that can serve as a roadmap when considering a high-efficiency industrial boiler for your facility.
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What distinguishes China's high-efficiency boiler manufacturers from competitors?
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What is the difference between standard and high-efficiency boilers?
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How does the water supply system of a high-efficiency steam boiler work?
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How does the steam supply system of a high-efficiency steam boiler operate?
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What are the shutdown operations of high-efficiency boilers?
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How should daily maintenance and upkeep of steam boilers be performed?
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What is the phenomenon, cause and treatment of boiler steam and water co-evaporation?
I. Understanding Boiler Efficiency and Lifespan:
What is a high efficient boiler?
CN-Boiler provides a high-efficiency boiler refers to a heating system that maximizes the utilization of energy to produce heat, minimizing waste and reducing environmental impact. It typically incorporates advanced technologies, such as condensing and modulating features, ensuring optimal fuel utilization. The efficiency is often measured by the AFUE (Annual Fuel Utilization Efficiency) rating, with higher percentages indicating more effective energy conversion. High-efficiency boilers contribute to cost savings, reduced emissions, and improved overall heating performance.
What are the Types of high-efficiency boilers?
Compact and efficient, ideal for small-scale steam applications, offering convenience and ease of use.
Robust design with tubes carrying hot gases through water, ensuring efficient heat transfer for various industrial uses.
Versatile boiler utilizing water for steam generation, suitable for diverse applications requiring reliable and continuous heat.
Tailored for medical facilities, ensuring reliable and sterile steam supply, meeting stringent healthcare standards.
Sustainable solution utilizing wood pellets as fuel, providing eco-friendly and cost-effective steam generation.
Efficient and environmentally conscious, utilizing coal as fuel while incorporating energy-saving technologies for sustainable steam production.
How long do high-efficiency boilers last?
1.Lifespan Range:
High-efficiency boilers typically have a lifespan ranging from 15 to 30 years.
2.Cation Exchange Resins:
Regular maintenance, proper installation, and adherence to manufacturer guidelines contribute significantly to the durability of high-efficiency boilers.
3.Maintenance for Longevity:
Routine inspections and timely repairs play a crucial role in extending the lifespan of high-efficiency boilers, ensuring reliable and energy-efficient heating over an extended period.
What distinguishes China's high-efficiency boiler manufacturers from competitors?
China's high-efficiency boiler manufacturers often stand out by virtue of advanced technology provided by foreign countries, a large amount of cheap labor in the country, a complete supply chain accumulated over many years that can provide cost-effective solutions, and rich experience in large-scale industrial projects. Advantages that manufacturers from other countries do not have.
In addition, their emphasis on research and development, coupled with their high emphasis on meeting strict environmental regulations, the Chinese government attaches great importance to the safety standards of high-efficiency boilers, and relevant government personnel review products and quality every month, making them in the competitive landscape stand out, and Chinese manufacturing has spread all over the world, proving the strong strength of Chinese manufacturers. So I highly recommend choosing products from Chinese manufacturers.
How efficient is a 10-year-old boiler?
Moderate Efficiency: A 10-year-old boiler, if well-maintained, can maintain reasonable efficiency levels, but it may not match the energy-saving capabilities of newer high-efficiency models.
Consideration for Upgrades: Regular monitoring and evaluation are essential, and homeowners may consider upgrading to more efficient models to enhance energy savings and overall performance.
How efficient is a 50-year-old boiler?
Considerable Decrease in Efficiency: A 50-year-old boiler is expected to have a notable decline in efficiency compared to modern standards due to aging components and outdated technology.
Upgrade Recommendation: Upgrading to a newer, high-efficiency boiler is advisable to enhance energy utilization, improve overall performance, and align with current efficiency standards.
Can a boiler last 20 years?
Potential Longevity: Boilers can potentially last for 20 years or more, with factors like quality, proper installation, and regular maintenance influencing their lifespan.
Maintenance Impact: Well-maintained boilers, undergoing routine inspections and repairs, are more likely to achieve extended lifespans.
Consideration for Efficiency: While longevity is essential, considering technological advancements and energy efficiency is crucial. For a reliable choice, CN-Boiler is recommended, known for quality and innovative solutions in the boiler industry.
Is it worth repairing a 20-year-old boiler?
Cost Consideration: Assess the cost of repairs against the potential benefits. Extensive repairs for a 20-year-old boiler may be expensive and may not guarantee long-term reliability.
Operational Efficiency: Older boilers may become less efficient even after repairs. Evaluating the long-term operational costs and efficiency gains is crucial.
Upgrade Option: Considering advancements in technology and energy efficiency, homeowners often find it more worthwhile to invest in a new, high-efficiency boiler rather than extensive repairs for an older model.
II. Comparing Boiler Efficiency and Performance:
What is the difference between standard and high-efficiency boilers?
Standard boilers operate with conventional technology, while high-efficiency boilers incorporate advanced features like condensing technology and modulating burners. High-efficiency models generally achieve better energy utilization and lower fuel consumption.
How do I know if my boiler is efficient?
Determining the efficiency of your boiler involves considering several indicators. Here's how you can assess if your boiler is efficient:
Check AFUE Rating: The Annual Fuel Utilization Efficiency (AFUE) rating is a crucial metric. It represents the percentage of fuel converted into usable heat. Higher AFUE ratings indicate better efficiency.
Regular Maintenance: A well-maintained boiler tends to operate more efficiently. Regular servicing, cleaning, and inspection can enhance performance and identify issues affecting efficiency.
Energy Bills Analysis: Monitor your energy bills. A sudden increase in energy costs may suggest reduced efficiency. Compare current bills to past records to identify any notable changes.
Age of the Boiler: Older boilers may be less efficient due to outdated technology. If your boiler is over 15 years old, upgrading to a newer, high-efficiency model could lead to improved performance.
Heating Patterns: Uneven heating or prolonged heating times may indicate efficiency issues. An efficient boiler should distribute heat evenly and reach the desired temperature promptly.
Unusual Noises or Odors: Odd sounds or smells may indicate mechanical issues affecting efficiency. Have a professional inspect the boiler if you notice anything unusual.
Burner Flame Inspection: If your boiler has a visible flame, check its color. A blue flame indicates efficient combustion, while a yellow flame may suggest incomplete combustion and reduced efficiency.
Importance of Adherence: Adhering to safety guidelines, conducting proper maintenance, and staying informed about industry regulations are essential to preventing accidents and ensuring the safe operation of boilers in various sectors.
Disadvantages may include higher upfront costs, specialized venting requirements, and potential complexity in repairs. These factors can offset long-term energy savings, influencing the overall cost-effectiveness.
Do boilers become less efficient over time?
Yes, boilers can become less efficient over time due to various factors. Here's why:
Wear and Tear: Components of the boiler, such as heat exchangers, valves, and pumps, undergo wear and tear with extended use. This can lead to reduced efficiency over time.
Deposits and Scale: Accumulation of deposits, scale, or sediment within the boiler can impede heat transfer and reduce overall efficiency. Regular maintenance is crucial to prevent these issues.
Burner Degradation: The combustion process within the burner can degrade over time, affecting the efficiency of fuel-to-heat conversion. Regular cleaning and adjustments are necessary to maintain optimal combustion.
Why are new radiators more efficient?
Design Improvements: Modern radiators often feature improved designs that enhance heat distribution and convection. They may have better fins, larger surface areas, and optimized shapes to maximize the transfer of heat from the radiator to the surrounding air.
Materials: Advances in materials technology have led to the development of radiators made from materials that conduct heat more effectively. Aluminum and other alloys are commonly used in modern radiators for their excellent thermal conductivity. Thermostatic Controls: New radiators often come equipped with thermostatic controls, allowing users to regulate the temperature more precisely. This not only improves comfort but also ensures that the radiator operates at the most energy-efficient level.
Energy Efficiency Standards: Many modern radiators comply with energy efficiency standards and regulations. Manufacturers design them to meet specific energy performance criteria, reducing energy consumption and operating costs.
Compact and Space-Efficient Designs: Modern radiators are often more compact and space-efficient. This is particularly beneficial for homes or buildings with limited space. Compact designs also contribute to better heat distribution.
Compatibility with Renewable Energy Sources: Some modern radiators are designed to work effectively with renewable energy sources, such as solar thermal systems or heat pumps. This allows for more sustainable and environmentally friendly heating solutions.
Improved Finishing and Coating: Radiators are often coated with materials that prevent corrosion and improve durability. This ensures a longer lifespan for the radiator and helps maintain its efficiency over time.
Easy Installation and Maintenance: Modern radiators are designed with ease of installation and maintenance in mind. This can make it more convenient for homeowners to upgrade their heating systems, encouraging the adoption of newer and more efficient models.
What makes a boiler inefficient?
Several factors can contribute to the inefficiency of a boiler. Here are common reasons why a boiler may operate inefficiently:
Age: Older boilers may lack modern efficiency features and utilize outdated technology, leading to decreased overall efficiency compared to newer models.
Lack of Maintenance: Inadequate or infrequent maintenance can result in the accumulation of deposits, scale, and dirt, hindering heat transfer and overall performance.
Incorrect Sizing: A boiler that is either too large or too small for the heating demands of a space may operate inefficiently, leading to wasted energy and increased operational costs.
Inadequate Insulation: Poor insulation in the boiler or its pipes can result in heat loss, reducing the system's efficiency and requiring more energy to maintain the desired temperature.
How can I increase the efficiency of my boiler?
Optimize Combustion: Ensure proper air-fuel ratio and regular burner maintenance for efficient combustion, reducing fuel wastage.
Regular Maintenance: Schedule routine inspections, cleanings, and component checks to address potential issues, maintaining peak efficiency.
Upgrade Insulation: Improve insulation around pipes and the boiler to minimize heat loss and enhance overall system efficiency.
Install a Programmable Thermostat: Implementing a programmable thermostat allows precise control over heating cycles, preventing unnecessary energy consumption.
III. Cost and Future Considerations:
Is it worth getting a high-efficiency boiler?
Investing in a high-efficiency boiler is often worth it due to substantial long-term energy savings, reduced environmental impact, and potential financial incentives. The higher upfront cost is generally offset by lower operational expenses.
How much will a high-efficiency boiler save?
The savings from a high-efficiency boiler can vary based on several factors, including the efficiency improvement, the energy prices in your region, and the amount of energy your home or business consumes. Here are some factors to consider when estimating potential savings:
Efficiency Improvement: High-efficiency boilers are designed to operate with greater efficiency, converting a higher percentage of fuel into usable heat. The efficiency of boilers is often measured by an Annual Fuel Utilization Efficiency (AFUE) rating. Older boilers may have AFUE ratings below 80%, while high-efficiency models can have AFUE ratings of 90% or higher. The higher the AFUE, the more efficient the boiler.
Fuel Type: The type of fuel your boiler uses (e.g., natural gas, oil, propane) affects the potential savings. Different fuels have different costs per unit of energy, and some may be more expensive than others.
Energy Prices: The cost of energy in your area plays a significant role in determining savings. If energy prices are high, the potential for savings from a high-efficiency boiler is greater.
Climate: The local climate also influences how much your heating system operates. Colder climates generally require more heating, leading to potentially greater savings with a high-efficiency boiler.
Usage Patterns: How often you use your heating system and the demand for hot water can impact savings. Homes or businesses with high heating demands may experience more significant savings. System Design and
Maintenance: Proper installation, regular maintenance, and an optimized heating system design contribute to efficiency. A well-maintained and properly installed high-efficiency boiler is more likely to achieve its rated efficiency and deliver optimal savings.
While it's challenging to provide an exact dollar amount for savings without specific details about your situation, upgrading to a high-efficiency boiler can result in noticeable energy savings over time. In some cases, the increased upfront cost of a high-efficiency boiler may be offset by reduced energy bills, leading to a return on investment over the life of the system. It's recommended to consult with a professional heating contractor to assess your specific circumstances and provide a more accurate estimate of potential savings.
What will replace boilers after 2025?
Future replacements may involve more sustainable heating technologies, including enhanced electric boilers, heat pumps, or other innovative solutions as the industry evolves to meet energy efficiency and environmental standards beyond 2025.
How many boilers explode a year?
Varied Incidence Rates: The annual occurrence of boiler explosions fluctuates and is influenced by factors such as boiler types, usage, and safety practices.
Stringent Safety Standards: The rarity of boiler explosions can be attributed to the implementation of strict safety standards and regulations within industries.
Regular Inspections: Routine inspections are a critical aspect of boiler safety, helping identify and address potential issues before they escalate into serious problems.
Modern Technologies: Advances in boiler technology contribute to enhanced safety features, reducing the risk of explosions through improved control systems and fail-safe mechanisms.
Importance of Adherence: Adhering to safety guidelines, conducting proper maintenance, and staying informed about industry regulations are essential to preventing accidents and ensuring the safe operation of boilers in various sectors.
IV.How does a high-efficiency steam boiler work?
How does the water supply system of a high-efficiency steam boiler work?
The water supply system is responsible for supplying soft water to the boiler and usually includes water softener, soft watr tank, water pump, deaerator, dosing device and other equipment.
Water softener: Industrial boilers generally use ion exchange methods to soften, remove alkali, and desalinize water. Commonly used water softeners include fully automatic operation and manual operation.
The specifications, resin loading, and salt consumption of the water softener are directly related to the hardness of the raw water. Correct selection based on the raw water conditions is crucial.
Fully automatic water softeners are divided into two types: time type and flow type according to their working control methods. Time type control regenerates and cleans ions according to a set time period, and flow type control regenerates according to the set amount of water passing through the water softener. and cleaning.
Soft water tank: used for the storage of treated soft water. Its volume should generally be greater than the water consumption of the boiler in one hour. The soft water tank can be constructed of concrete, carbon steel, stainless steel, etc. The soft water tank should undergo internal anti-corrosion treatment.
Water pump: The water pump of the water supply system is equipped with a deaeration water pump and a boiler feed water pump.
The deaeration water pump supplies water to the deaerator from the soft water tank. The flow rate should be slightly larger than the water consumption of the boiler, and the lift is usually about 25m.
The boiler feed water pump supplies water to the boiler from the deaerator. The flow rate is greater than or equal to the water consumption of the boiler. The lift should generally be greater than the rated pressure of the boiler plus 25m.
Deaerator: Boilers with an evaporation capacity ≥10t/h should be equipped with a deaerator. The commonly used deaerator in industrial boilers is a thermal deaerator.
WNS boilers are generally equipped with atmospheric thermal deaerators, with a working pressure of 0.02Mpa and a working temperature of 104°C. The deaerator output is determined based on the boiler's rated evaporation capacity and the system's condensate recovery volume. If there is no condensate water return, the deaerator The output is equal to the boiler's rated evaporation capacity. The deaerator water tank at the bottom of the deaerator can be used as a boiler feed water tank, and its volume is mostly 50% of the deaerator output.
Sampling cooler: used for pot water and steam sampling, using cooling water to cool the high-temperature medium flowing through the sampler to prevent
Steam and pot water evaporate during sampling and cause sampling errors, while preventing burn accidents during sampling. The boiler water sampling point is generally selected on the drain pipe of the boiler surface sewage pipe. If there is no surface sewage drain, it can be selected on the drain pipe of the water level meter. The steam sampling point should be selected on the main steam pipe of the boiler, and there must be a 6D (main steam pipe diameter) straight pipe section in front of the sampling point.
Dosing device: used to add chemicals into the pot to improve water quality and loosen scale. The dosing device usually uses an electromagnet-driven diaphragm metering pump for continuous metering and delivery.
How does the steam supply system of a high-efficiency steam boiler operate?
The steam supply system supplies steam produced by the boiler to the production equipment through separate cylinders.
Sub-cylinder: The boiler supplies steam to the heating system through sub-cylinders. The standard sub-cylinder interfaces for boilers with an evaporation capacity below 10t/h are one in and four out. The standard sub-cylinder interfaces for boilers with an evaporation capacity above 15t/h are one in and five. Out, the cylinder interfaces with special needs can be designed as needed.
How does the steam boiler’s sewage system operate?
Continuous blowdown expander: used for continuous blowdown of boiler surface dirt and reduction of boiler water salt content. Skimming the water surface removes dissolved solids such as phosphates and silica, potassium, sodium, magnesium, soluble calcium, chloride, etc. The sewage is separated into steam and water through a continuous sewage expander, and the steam is recycled (generally connected to a thermal deaerator). The working pressure of the continuous blowdown expander is generally 0.2Mpa, and its specifications are divided by volume. The four commonly used specifications are 0.7/1.5/3.5/5.5m3.
Fixed blowdown expander: used for regular discharge of undissolved solids at the bottom of drums and header tanks. The sewage is silenced, cooled and steam recovered through the fixed sewage expander. The working pressure of the fixed sewage expander is generally ≤0.15Mpa, and its specifications are divided by volume. The four commonly used specifications are 0.8/3.5/7.5/15m3.
What are the shutdown operations of high-efficiency boilers?
Boiler shutdown is generally divided into four situations: temporary shutdown, temporary shutdown, complete shutdown, and emergency shutdown.
Temporary malfunction shutdown
If equipment such as the combustion system or water supply system fails, and the failure can be resolved in a short time, the furnace should be shut down temporarily.
Temporary shutdown
During menstrual holidays or other situations, the furnace should be temporarily shut down when steam is not used in a short period of time. Temporary shutdowns are planned. In addition to paying attention to safety and properly maintaining equipment during shutdowns, fuel and water conservation must also be achieved.
Complete shutdown
For cleaning, inspection or repair purposes, the boiler should be shut down completely when not in use for a short period of time. Complete shutdown of the furnace should be planned. Generally, the furnace should be shut down once every 1-3 months of operation. Pay attention to safety and equipment maintenance when shutting down the furnace.
Emergency shutdown
In the event of special circumstances or major boiler failure, the boiler must be shut down urgently for the sake of safety and reliability.
When the boiler is in operation, if one of the following situations occurs, the boiler should be shut down in an emergency and the relevant departments should be notified.
1) The water level cannot be seen in the glass tube of the water level meter. If the water level is still not visible even after using the "call for water" method, no sudden water intrusion is allowed;
2) Continuously increase the water supply to the boiler and take other measures, but the water level continues to drop;
3) When the boiler water level has risen above the upper water level limit specified in the operating regulations;
4) All water supply equipment fails;
5) All water level gauges, safety valves, and pressure gauges, one of them all failed;
6) Cracks are found in the main parts of the boiler (drum, header) or pipe bursts occur in the main steam pipe, water wall pipe, economizer, and condenser pipe;
7) The combustion equipment and furnace walls are seriously damaged, threatening the safe operation of the boiler;
8) Other normal operation conditions and exceeding the allowable safe operation range.
Emergency shutdown should focus on preventing the accident from expanding. First, quickly close the fuel supply pipe valve, open each flue door, and continue to maintain ventilation to reduce the temperature in the furnace. Under normal circumstances, no water can enter the furnace during emergency shutdown, and the boiler can be allowed to cool naturally.
What are the precautions for normal operation of high-efficiency boilers?
When the boiler is operating normally, it is required that: the water level in the boiler is normal, the steam pressure is stable, the boiler room is kept clean, and the shift handover work is carried out. Comply with the job responsibility system and strengthen supervision of various mechanical equipment and instruments. Ensure safety and reliability, prevent accidents, and pay attention to saving fuel. Stoker workers should regularly summarize operating experience and continuously improve operating levels.
1) Water level in the pot: Always pay attention to changes in the water level in the pot, and keep it within the range of ±25 mm from the normal water level. It should not be higher than the highest or lower than the lowest water level. The water level in the water level meter generally sways slightly. If the water surface is still, If it moves, the water level meter may be clogged and should be flushed immediately.
2) Water level meter: The glass tube of the water level meter should be kept clean and tidy to ensure that the water level is clear, correct and reliable. If water or air leakage is found in the glass tube gasket, the packing should be tightened. If the glass is blurry or the water level is unclear, it should be replaced if flushing still has no effect. Each boiler is equipped with two water level gauges. If one of them is found to be damaged, it should be repaired immediately. If both are damaged at the same time, the boiler should be temporarily shut down immediately until one water level gauge returns to normal before it can continue to operate.
3) Pressure gauge: The pressure gauge must work normally. If the pressure gauge is found to be damaged, the furnace should be shut down immediately for repair or replacement. The pressure gauge should be calibrated every six months. If the reading difference exceeds ±2.5%, it should be repaired or replaced.
4) Safety valve: Pay attention to the normal operation of the safety valve, and the safety valve should be calibrated once a year.
5) Water supply equipment: All water supply pumps should be operating normally, and start-up inspections are required during shift handover. If there is a fault, repair it immediately. The boiler feed water should be fed continuously as much as possible to stabilize the steam supply pressure and reduce the changes in hot and cold conditions in the boiler.
6) Steam pressure: Always pay attention to pressure changes, keep the pressure in the pot stable, and do not let the steam pressure exceed the maximum allowable working pressure.
7) Sewage discharge: Do a good job in sewage discharge according to regulations.
Daily maintenance and upkeep of steam boilers
A steam boiler is an industrial boiler that heats water to certain parameters and produces high-temperature steam. It is a special equipment. Water is heated in the drum and turns into steam, and fire emits heat in the furnace. This is the principle of a steam boiler. As steam boilers receive more and more attention from everyone, the daily maintenance and upkeep of steam boilers should be taken seriously regardless of the environment.
Routine inspection of steam boilers is very important, mainly in the following places.
1. Boiler inspection
1. The newly installed boiler needs minor repairs once a month, minor repairs every three months and major repairs once a year;
2. Minor repairs to major boiler equipment:
1). Eliminate defects found during operation;
2). Focus on repairing easily worn parts and perform necessary cleaning or testing;
3). Before a major repair, a minor repair should be inspected and the overhaul items should be verified;
3. Overhaul of major boiler equipment:
1) Carry out more comprehensive inspection, cleaning and repair;
2) Eliminate equipment defects;
3) Carry out prescribed tests and identifications;
4) Boiler overhaul projects can be specifically formulated with reference to the "Small Boiler Operation Regulations" and "Power Plant Maintenance Regulations";
4. Main maintenance items during the overhaul of major boiler equipment:
1) Inspect the corrosion and scale inside the upper and lower headers, and check whether there are cracks and cracks in their welds;
2) Whether there is wear and corrosion on the outer wall of the pipe, especially the pipe wall where the flue gas flow rate is high;
3) Whether the headers and pipes are dented, bent, bulged or overheated;
4) Is there any corrosion at the contact point between the header box and the brick lining?
5) Whether the metal parts of the boiler are overheated;
6) Check whether there are any corrosion or cracks at the interfaces between the water supply pipe, sewage pipe and the drum;
7) Whether the safety valve, pressure gauge, and water level gauge are qualified, and whether the openings are blocked;
8) Whether the automatic control system and instruments are flexible and reliable.
2. Regular inspection
1. Boilers undergo regular inspections, including external inspections, regular boiler shutdown internal and external inspections, and hydraulic pressure tests;
2. The quality and technical supervision department should participate in the regular shutdown inspection and hydraulic pressure test of the boiler;
3. Operational boilers should undergo internal and external inspections once every two years. New boilers should undergo internal and external inspections every year during the first two years of operation. After the boiler has been in operation for 10 years, internal and external inspections should be conducted every year. Water pressure tests are generally conducted every six months. Conducted once a year;
4. In addition to periodic inspections, internal and external inspections and hydraulic pressure tests should be carried out when the boiler has one of the following conditions:
1) When newly installed, relocated or out of operation for more than one year, it needs to be put into operation or restored to operation;
2) After the pressure-bearing components have undergone major repairs and modifications;
3) When there is doubt about the condition of the equipment based on the operation of the boiler;
3. Boiler maintenance
1. The feed water to the boiler must undergo strict treatment. This is an important matter to extend the life of the boiler and ensure safe operation. The softening treatment quality of the feed water should be implemented in accordance with GB/T1576-2008 "Industrial Boiler Water Quality".
2. The feed water temperature should be as close as possible to the temperature of the furnace body, and its temperature should preferably be above 20°C;
3. It is very important to ensure the normal operation of water level control. Lack of water is one of the main causes of boiler accidents and damage. The low water level cut-off device must be inspected and maintained regularly. The flushing water level gauge should not be lower than the lowest safe water level. If it is not clean after one flush, it can be flushed multiple times. But it must be flushed at the highest water level. The steps for flushing the water level gauge have been detailed previously.
4. In order to remove sediment and mud at the bottom of the boiler and reduce the concentration of boiler water, sewage blowdown operations need to be carried out regularly, at least once a day, and the sewage blowdown rate should not be greater than 3%. After the sewage is discharged, regularly check whether the sewage valve is leaking due to the influence of dirt; if so, it must be eliminated. To maintain the water level, please refer to the water level meter flushing method.
5. When the boiler is out of service, anti-corrosion measures must be taken and maintenance work must be done.
How to improve the thermal efficiency of steam boilers?
1. Boiler water quality control: Maintain appropriate boiler water quality, prevent the generation of scale and sediment, and reduce corrosion problems inside the boiler.
2. Combustion control: Combustion system components such as strategies, procedures and instrumentation play a decisive role in combustion quality. Optimize gas combustion to ensure sufficient oxidation and heat release, which can improve thermal efficiency.
3. Heat recovery: Collect the heat in flue gas or wastewater in an economical and reasonable way so that it can be reused to improve energy efficiency.
4. Boiler heat balance control: Control performance parameters such as flow, temperature, pressure, etc. to obtain optimal combustion that meets the heat demand generated.
5. Energy-saving design: Under the premise of ensuring normal operation under temperature conditions, try to design energy-saving pipes, equipment, etc. to reduce energy loss in heat transmission.
What is the phenomenon, cause and treatment of boiler steam and water co-evaporation?
Phenomenon:
1. The water level in the steam drum water level gauge fluctuates sharply, the water level cannot be seen clearly, and there is foam.
2. In severe cases, the temperature of the superheated steam drops sharply, water impact occurs in the steam pipe or steam emerges from the flange.
3. The salt content of steam increases.
reason:
1. The quality of feed water or boiler water exceeds the specified value.
2. Failure to discharge sewage as required or improper chemical dosing.
3. The soda-water separation equipment is defective.
4. The boiler load suddenly increases or the steam pressure drops sharply.
deal with:
1. Report to the duty leader to open the emergency water release door and keep the water level running.
2. Turn down or close the desuperheating water door and open the superheated steam drain door.
3. Strengthen regular sewage discharge work and open the Dalian discharge adjustment door.
4. Contact the steam turbine to reduce the unit load and keep the load stable.
5. Contact chemical sampling and testing to improve boiler water quality.
6. It is not allowed to increase the unit load before the boiler water quality is improved.
7. After the fault is eliminated, the water level gauge should be flushed and calibrated once.
How to achieve energy-saving operation of steam boilers?
Energy-saving operation of steam boilers can be achieved by optimizing combustion methods, reducing heat loss, and recovering waste heat.
1. According to the amount of steam required for industrial production, rationally select the rated power of the steam boiler and the number of boilers. The better they match the actual use, the smaller the exhaust loss will be, and the energy-saving effect will be more obvious.
2. Let the appropriate amount of fuel contact the appropriate amount of air to form a high-quality ratio for combustion, which can effectively improve the combustion efficiency of the fuel and reduce the emission of polluting gases, effectively achieving the dual purpose of energy saving.
3. The thermal efficiency of commonly used boilers is between 85% and 88%, and the exhaust gas temperature is between 220 and 230 degrees. Lower the boiler exhaust temperature to effectively utilize the waste heat generated in the exhaust smoke. If an energy saver is installed to utilize the heat energy of the exhaust smoke, The exhaust gas temperature can be reduced to 140-150 degrees, and the thermal efficiency of the boiler can be increased to 90%-93%.
4. Utilize the heat in the continuous wastewater through heat exchange to increase the feed water temperature of the deoxygenated water, thereby achieving the purpose of energy saving for the gas boiler. The condensate water in the heating system can also be reasonably recovered, and recycling the heat of the condensate water is also an energy-saving way.
5. Installing a boiler economizer can also save energy. The purpose of the boiler economizer is to recover the waste heat of the flue gas. It is classified according to the specific use and exchange medium.
What is the calculation formula for a steam boiler?
Boiler formulas are useful tools for anyone who operates or installs boilers. In this article we will provide some useful boiler formulas, along with a few other calculations you can use with your system.
All formulas on this page are typical in nature and will change with actual site conditions, equipment capabilities, efficiencies, etc.. These are offered as a general means of estimating requirements or conditions without all necessary values known. Assuming a boiler ‘Fuel to Steam’ efficiency of 80%：
Step 1: Determine the properties of the generated steam
Take advantage of the steam property calculator. Determine steam properties using steam pressure and selected secondary parameters (temperature, specific enthalpy, specific entropy or dryness). The specific enthalpy is then multiplied by the mass flow to obtain the energy flow.
★ Steam energy flow =specific enthalpy x mass flow
Step 2: Define Feed Water Energy and Mass Flow
From the steam mass flow rate and the blowdown rate, the make-up water flow rate can be calculated. Sewage mass flow = supply water mass flow x sewage rate Steam mass flow = Supply water mass flow - Sewage mass flow Steam mass flow = supply water mass flow - supply water mass flow * blowdown rate Supply water mass flow = steam mass flow / [ 1 - blowdown rate ] Using the Steam Properties Calculator, determine the steam properties from the deaerator pressure and steam fraction = 0 (saturated liquid). The specific enthalpy is then multiplied by the mass flow to obtain the energy flow.
★ Supply water energy = specific enthalpy * mass flow rate
Step 3: Define Blowdown Characteristics and Mass Flow
Using the calculated feedwater mass flow and air release rate Sewage mass flow rate = Supply water mass flow rate x Sewage discharge rate Using the Steam Properties Calculator, determine the steam properties from the steam pressure and steam fraction = 0 (saturated liquid). The specific enthalpy is then multiplied by the mass flow to obtain the energy flow.
★ Blowdown energy flow = specific enthalpy * mass flow
Step 4: Define Boiler Efficiency
★ Boiler energy = steam energy flow + sewage energy flow - water supply energy
Step 5: Define Fuel Efficiency
★ Fuel Energy = Boiler Energy / Combustion Efficiency
Steam Boiler Explosions in the United States：The records kept by the Hartford Steam Boiler Inspection and Insurance Company show that 170 steam boilers exploded in the United States last year, killing 259 persons and injuring 555. The classified list shows the largest number of explosions in any class to have been 47, in sawing, planing and woodworking mills.
Here are some excellent steam boiler manufacturers, including CN Boiler:
CN Boiler is a company with a high reputation in the field of steam boiler manufacturing. They focus on producing high-quality, high-efficiency steam boilers and are leaders in technological innovation and product quality. CN boiler products are widely used in industrial production, heating systems, power plants and other fields. Their industrial steam boilers not only have stable and reliable performance, but also focus on energy conservation and environmental protection, complying with modern environmental protection requirements.
Conclusion:
In conclusion, exploring the realm of high-efficiency boilers through our 30 questions has provided valuable insights into their functionality, benefits, and considerations. These questions have aimed to address common queries, assisting you in making informed decisions about high-efficiency boiler systems.
For further knowledge and expertise on high-efficiency boilers, consider reaching out to reputable manufacturers like CN-Boiler, known for their excellence in producing high-quality and customized boiler solutions. Whether for residential or commercial needs, CN-Boiler offers professional advice, a range of products tailored to diverse requirements, and dedicated service to ensure your heating systems meet the highest standards of efficiency and performance. Explore the possibilities with CN-Boiler for an optimized and energy-efficient heating experience.
Appendix
Figure 1 for Boiler Water Quality Requirement (GB/T1576-2018)
|
Item
|
Rated steam
pressure /MPa
|
P≤1.0
|
1.0
|
1.6
|
2.5
|
|||||
|
Make-up water type
|
Soften
water
|
Demineral
ized water
|
Soften
water
|
Demineral
ized water
|
Soften
water
|
Demineral
ized water
|
Soften
water
|
Demineral
ized water
|
||
|
Feed
water
|
Turbidity/ FTU
|
≤5.0
|
≤2.0
|
≤5.0
|
≤2.0
|
≤5.0
|
≤2.0
|
≤5.0
|
≤2.0
|
|
|
Hardness/(mmol/ L)
|
≤0.03
|
≤0.03
|
≤0.03
|
≤0.03
|
≤0.03
|
≤0.03
|
≤0.005
|
≤0.005
|
||
|
PH Value/25℃
|
7~9
|
8~9.5
|
7~9
|
8~9.5
|
7~9
|
8~9.5
|
7~9
|
8~9.5
|
||
|
Dissolved
oxygen/(mg/ L)
|
≤0.1
|
|
≤0.1
|
≤0.05
|
≤0.05
|
≤0.05
|
≤0.05
|
≤0.05
|
||
|
Oil(mg/ L)
|
≤2.0
|
≤2.0
|
≤2.0
|
≤2.0
|
|
|
≤2.0
|
≤2.0
|
||
|
Total iron/(mg/ L)
|
≤0.3
|
|
|
|
≤0.3
|
≤0.1
|
≤0.1
|
≤0.1
|
||
|
Electrical
conductivity(25℃ )/( μS/cm)
|
|
|
|
|
|
|
|
|
||
|
Boiler
water
|
Total
alkalinit y/(mm ol/ L)
|
No
superhe ater
|
6~26
|
|
|
|
6~ 16
|
|
|
|
|
Superhe ater
|
一
|
-
|
≤14
|
|
≤12
|
≤8
|
|
|
||
|
Phenol phthale in
alkalinit y(mmol / L)
|
No
superhe ater
|
4~ 18
|
|
|
≤6
|
|
|
≤10
|
|
|
|
Superhe ater
|
-
|
一
|
|
|
|
|
≤10
|
|
||
|
PH value/(25℃)
|
10~ 12
|
10~12
|
10~ 12
|
10~ 12
|
10~ 12
|
10~12
|
9~ 12
|
9~ 11
|
||
|
Dissolv
ed
solids/( mg/ L)
|
No
superhe ater
|
≤4000
|
≤4000
|
|
≤3500
|
|
≤3000
|
≤2500
|
≤2500
|
|
|
Superhe ater
|
|
-
|
≤3000
|
≤3000
|
≤2500
|
≤2500
|
≤2000
|
≤2000
|
||
|
Phosphate/(mg/ L)
|
-
|
|
10~30
|
10~30
|
10~30
|
10~30
|
5~20
|
5~20
|
||
|
Sulfite/(mg/ L)
|
-
|
-
|
10~30
|
10~30
|
10~30
|
10~30
|
5~ 10
|
5~ 10
|
||
|
Relative alkalinity
|
<0.2
|
<0.2
|
<0.2
|
<0.2
|
<0.2
|
<0.2
|
<0.2
|
<0.2
|
||
Figure 2 for Air Pollutants Emission Standard Limit of New Boiler(GB13271-2014)
|
Pollutant Item
|
Limit Value
|
Pollutant emission
monitoring
position
|
||
|
Coal fired boiler
|
Oil fired boiler
|
Gas fired boiler
|
||
|
Particulate matter/(mg/ m3)
|
50
|
30
|
20
|
Chimney or flue duct
|
|
Sulfur dioxide/(mg/m3)
|
300
|
200
|
50
|
|
|
Nitrogen oxides/(mg/ m3）
|
300
|
250
|
200
|
|
|
Mercury and other compounds/(mg/m3）
|
0.05
|
-
|
-
|
|
|
Flue gas blackness(Ringelmann
blackness grade)
|
≤1
|
The chimney outle
|
||
