Buying an Industrial Boiler: Critical Features to Consider

Buying a commercial boiler for your industry needs is not something to take lightly. It&#;s an expensive piece of equipment that needs to function properly for many years to come.

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The last thing you want to do is buy the wrong boiler and end up having to spend extra money on repairs. You also don&#;t want to have to buy another boiler long before you planned on doing so, wasting even more money. To prevent these from happening, here are the most important factors to consider when selecting a new industrial steam boiler.

Getting More Efficiency for the Price

Obviously, the price of a boiler system has to receive some consideration. Everyone has a budget, and you need to buy a boiler that fits into that budget. However, you may not want to skimp on price when it comes to buying a boiler. If you settle for a cheap, inferior product, you may end up spending more in the long run on repairs or replacing the boiler sooner than expected.

Efficiency is actually a more important factor to consider when it comes to selecting a new boiler. When you buy a steam boiler, you need to look at the overall cost of operation, not just the price of the unit. An inefficient boiler will consume more fuel, causing energy bills to rise. In this sense, it may be better to spend a little more on a boiler with higher thermal efficiency, knowing it will save you money in the long run. Miura boilers have been shown to reduce fuel costs by up to 20%. Over the lifecycle of a boiler, which could be 15 to 20 years, saving that much on energy costs could end up being a significant amount of savings.

Firetube Vs. Watertube Boilers

Another key factor to consider is the type of boiler itself&#;specifically the heat transfer design of the boiler system. Most conventional boiler systems are fire tube boilers, in which hot gases pass through tubes immersed in the water to heat it. Watertube boilers take the opposite approach: the water passes through a tube that is surrounded by hot flue gas. The difference between these designs is that water tube boilers can convert water to steam in a very short period of time, requiring much less startup time and consuming less fuel in the process.

Watertube boilers also take up less space while providing enough steam output to accommodate most industrial processes. Miura specializes in producing high-quality watertube boilers, which many industries find preferable to conventional fire tube boilers.

When Size Matters: Space Considerations

The size of the boiler matters in the sense that you have to be able to fit it in your boiler room. Generally, you&#;ll want a boiler to have as small of a footprint as possible, as it will help to save both space and money. Miura&#;s modular boiler design helps to keep boilers as small as possible without sacrificing output or efficiency. The smaller boiler helps create flexibility with regard to space, as there is no need for tube pull-space or door-swing space like with traditional boilers.

This creates additional space in the boiler room and may even open the door for multiple modular boilers working on the same system to help improve efficiency and cut operating costs even further.

Safety Is a Must

Safety should always be one of the top priorities when buying a new boiler. Conventional steam and hot water boilers sometimes become overheated to the point that the build-up of high-pressure steam can cause a catastrophic explosion. One way to mitigate this risk is with a boiler system specifically designed for low water content operation. With low water content boilers, the amount of steam build-up is not enough to do excessive damage even if the unit malfunctions.

Another risk with conventional boilers is in the physical design itself. Performing maintenance on these units requires opening extremely heavy steel doors, realigning them, and closing them again, all while standing on a ladder &#; an invitation to a variety of injuries ranging from back pain to severe limb injury.

When it comes to safety, Miura boilers have an impeccable track record. Miura&#;s steam boilers are designed with no heavy doors, and their low water content design makes a catastrophic explosion virtually impossible. With over 140,000 units in operation all over the world, Miura has never experienced a pressure vessel explosion in one of its boilers.

Stay Ahead of Emissions Regulations

With growing concerns about air pollution, greenhouse gases, and the environment, manufacturers are under increasing pressure to reduce the amount of harmful emissions caused by their industrial processes. Much of the emissions problems companies face stem from the use of conventional boiler systems. Even when using &#;clean&#; natural gas, these boilers are notorious for expelling large amounts of CO2 and toxic nitrogen oxides (NOx) into the atmosphere, damaging the environment and often causing respiratory issues.

There are, however, alternative boiler designs that can significantly reduce the rate of harmful emissions. Miura boiler systems require far less fuel to operate and can easily power down when not needed. They also are designed for low to no NOx emissions, making it much easier for companies to comply with state and local emissions standards.

Maintenance Made Simple and Seamless

Last, but certainly not least, you need to consider how much long-term maintenance and upkeep your boiler will need in order to function at its best for as long as possible. A low-quality boiler may require frequent repairs, which will not only cost extra but may also force you to replace the boiler sooner than expected. A well-maintained steam system involves more than just the condition of the pressure vessel itself. It also involves having a good water treatment process in place to prevent mineral build-up and ensure proper working of your feedwater tanks, deaerator tanks, and reverse osmosis systems. Having an effective monitoring and control system can also help you identify and fix small problems before they turn into big ones, and you&#;ll also want a robust troubleshooting/maintenance support plan in place for routine maintenance issues.

Miura offers a full array of accessories and support systems designed to cover all aspects of your boiler system maintenance &#; from state of the art remote monitoring to water treatment to troubleshooting support. Miura also offers a boiler maintenance program that only requires a three-hour shutdown for routine inspections. Such inspections, as well as our monitoring system, will help keep your boiler running efficiently and safely for a long time to come.

Contact Miura today to learn more about modular boilers and how they can help your business save money.

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Boilers
Carey Merritt

What is the basis for design? It should be the specific features of the application that defines your process and operating environment. These 10 tips can help you identify points to consider.

Selecting the right steam boiler for an application can be daunting experience.
Manufacturers have creative marketing folks that tout features that can mislead anyone who does not fully understand what attributes make a good steam boiler. However, there is no one perfect boiler; instead, each boiler design has features that make it a good choice &#; or a bad choice &#; depending on how it will be used.

The ideal boiler only exists in the minds of sales people. The following list includes 10 features to consider when selecting the optimal boiler for your application. One can see some of the features are contradictory; therefore, a boiler that encompasses all 10 features cannot exist. Instead, the specifying engineer must align a boiler type with certain features with each unique application. Failure to do so likely will result in poor performance and an unhappy customer. Here are 10 features you wish every boiler had.

1 High Pressure Vessel Mass

The mass of the boiler will be a good indication of the amount of metal used to manufacture the pressure vessel. Mass is related to thickness and thickness is related to durability. Inherently, low mass boilers will not last as long as high mass boilers.

2 High Water Volume

2High Water Volume Water under pressure will store steam. Higher water volume means higher stored steam. Applications where you have rapid swing loads will require a high water volume boiler design.

3 High Efficiency

3High Efficiency We all would like to have the most efficient boiler. Efficiency, however, must be defined and compared on equal terms. Often, savvy marketing people publish efficiency based on certain unrealistic conditions such as using a low temperature feed water. Ensure boiler pressure, feed water temperature, firing rate, fuel BTU value and stack CO2 levels are all defined on the same playing field.

4 Quick Startup Times

4Quick Startup Times Simply put, you want steam in a reasonable time frame. Boilers that can make steam quickly likely will have low water and low mass, which may be non-desirable features. One must also realize a quick startup will facilitate a quicker cool down. The boilers on the market today typically require 5 to 20 minutes startup time.

5 Low Footprint

5Low Footprint Boiler room real estate is quite valuable these days and the less room a boiler occupies, the better. Vertical type boilers have an advantage in floor space demands, but they are limited somewhat by the height of the boiler. Therefore, they are not practical above a certain output. Be sure you take into consideration the amount of room required to perform maintenance on the boiler as part of the overall footprint

6 Low Heat Flux and High Heating Surface Area

Heat transfer is represented by the equation Q =m x Cp x ÄT where m is the heating surface area. Most heating surface area listings are for the fire-side surface area, with higher fire-side surface area values indicating higher the heat transfer efficiency. However, one also must consider the wetted heating surface area. The wetted heating surface area determines heat flux. Consequently, low wetted heating surface area can have very high heat flux, which can create higher metal temperature and increase scaling potential. Boilers with high fire-side and high wetted heating surface areas will be the most efficient and have low heat flux.

7 Ease of Clean Out

7Ease of Clean Out This is a measure of effectiveness of blow down and ability to keep the pressure vessel clean. Vertical boilers may have the advantage with this parameter because the pressure vessel orientation lends itself to easier clean out. Boilers with lots of small tubes or dead spots will not fair well in this category.

8 Effective Turn down

8Effective Turn down This feature has a lot to do with the burner performance. Effective turn down is a measure of how low the fuel input and air can be adjusted to maintain good combustion efficiency. Some burners will turn down the fuel but leave high excess air on low fire. This will create high turn down but poor overall combustion efficiency. Look at the highest turn down level while still maintaining good combustion efficiency.

9 Ease of Maintenance

9Ease of Maintenance Hardly ever will a specifying engineer think about maintenance when selecting a boiler. They should. Blow down valves, stack location, feed water inlet, control panel location, tube removal, burner removal and gas piping maintenance should all be considered as criteria of boiler selection.

10 Large Steam Disengagement Area

Like heating surface area, the more steam disengagement area, the better. Higher steam disengagement area produces higher steam quality, especially for low pressure steam applications. Consequently, horizontal boilers generally will produce higher steam quality than a vertical boiler of the same output.

All specifying engineers should consider these 10 features when specifying what boiler will be the basis of design. For example, if floor space is an issue, footprint will be the dominant feature. Likewise, if swing loads are expected, then a boiler with high water content will be the best choice. Some applications will require certain features not be compromised while other will be more forgiving. A successful installation will match features to the application.

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