Choosing the right 5 ton/h industrial coal boiler for your specific facility can be challenging, given that it is a huge investment. So, it is ideal that everything is clear beforehand, like the energy requirements, emissions, cost per capita, and the plant area. It helps you make wise decisions and save your money.
The good thing is that the price of a 5 ton steam boiler is relatively minimal. So, you are free to choose quality equipment that will increase efficiency and make the setup easy to maintain. To help you with the selection process, here is a complete guide on these industrial 5 ton steam boilers.
Role of 5 Ton/h Industrial Coal Boilers
A 5 ton/h industrial coal boiler is a setup that produces steam under specific pressure. In the chamber, the pressure increases to a level and becomes more than the external atmospheric pressure and generates steam. Steam production happens in large burners that are responsible for boiling water, with few resources.
The steam is further passed down to the industries for working through big pipelines. The reason why a 5 ton coal boiler is common is that it can fulfill a large level of energy requirement. Moreover, steam boiler coal is a fuel that is safe, has a simple burning process, and requires little investment. Also, this setup has minimal waste, Hence, it is perfectly compatible with the Federal Regulations on Emission Control.
Working Principle of Industrial boiler 5 ton
Wood coal fired boiler works best for industrial usage. Partly because they are less expensive and effective for large-level energy requirements. Having said that, there is much more that goes into the setup process. Unlike other types of fuel, these boilers use massive containers and burners to produce steam.
There are a number of components present. These include everything from heat exchangers to pipelines, combustion chambers, and exhaust stacks. Now, the real deal is that you can find two types of industrial boilers that use coal as fuel, called water tube and fire tube boilers. Nowadays, industries prefer using fire tube boilers. This is partly because the other ones are a bit on the expensive side and have less practice for a commercial setting.
FireTube Coal Boilers
When it comes to fire tube boilers, they work on convection alone and don’t require external heating elements. First of all, after the coal is in the system for burning, it produces heat. This heat then passes through the pipes into the chamber and eventually into the pipes. Here, the water is already boiling because of the increase in temperature.
After this, the superheater separates the steam from the water using the circulation process. This step quickly evaporates the water and leaves you with steam. From here, steam is a great alternative for day-to-day work, and the remaining ash is waste. From here, you can reuse the smoke for specific operations. And the ashes and dust pass through and out of the chimney.
To maintain efficiency, the entire setup has a firebrick casing that provides the insulation. Inside the system, there are different tubes positioned in a vertical position. The outer material saves these from high temperatures while they are in direct contact with high convection flames.
Measuring Efficiency of a 5 Ton/h Coal Boiler
When it comes to the 5 ton/h industrial boilers, their main purpose is to use the maximum extract from the fuel. This provides industries with massive energy production at the lowest cost. Hence, the first thing that determines the efficiency of a 5 ton boiler is the equipment quality and usage. This must be chosen to keep the output needs in check.
Now, the efficiency further depends on the heat losses in the system. The entire setup requires the designers to monitor the environmental factors. This helps them in getting the maximum benefit of the 5 ton/h industrial coal boiler. Here are some considerations that are critical for the efficiency of the coal-fired burner setup.
Flue Gas Temperature
In simple words, this temperature is that of the gasses that are leaving the chamber. So, if these gasses are really hot while they are emitting, it means the production of steam is not accurate and is lost during the process. To prevent this, it is important that industries have their maintenance setup that prevents this heat loss.
The ambient temperature equally matters while measuring the efficiency of a steam boiler. It is the hotness with which the gasses enter the system. Thus, it affects the net stack temperature, the difference between both. As per the stats, each 40 degrees change in this can impact the efficiency to 1%. As a result, finding the right balance can deliver well.
In an industrial coal boiler, the energy losses are in two forms. The radiation and convection losses that emit out of the system as heat. Well, no one can completely eliminate them, yet minimizing them can solve many problems. What you can do here is control the airflow in the boiler. So, an enclosed space can deliver well in keeping the outdoor air away.
Ways To Improve Efficiency
You must be wondering how you can maximize the usage of fuel. Well, here are some tips everyone should know before installing an industrial 5 ton boiler.
- The bottom ashes are a great source of heat energy. So, you can reuse them for industrial applications wisely.
- It is absolutely important to use all the fuel during combustion. This will leave no waste at the end and a high level of energy.
- Also, keeping the airflow and the number of gasses in check can increase the output. All in all, controlling 5% of the air will provide you with an increase of 1% in the boiler’s efficiency.
- Boiler maintenance is equally worth considering. This is because it decreases the chances of dry flue gasses in the chamber, which can increase heat losses.
- Water blowdown is another way of reducing heat losses. The process can eliminate any mineral build-up from the water and keep the liquid at an optimum level.
How to Find a Quality 5 Ton/h Coal Boiler
Now, you must be wondering what the considerations are while purchasing one. Well, here are some important things you must look into before making this heavy investment:
Fire Tube or Water Tube?
When it comes to the 5 ton/h industrial coal boiler size, we need to consider how to process the heat. It is pretty understandable that the setup is for massive energy requirements. Hence, a firetube convection system will work better. This is because it uses coal-fired steam in large chambers without external heat. The remaining smoke also can work great for commercial applications.
When we talk about industrial coal boilers, facilities have their own combustion technology. Some use a stoker that burns the fuel on a moving grate while others have fluid heaters with petroleum-based fluids. The technology determines the thermal efficiency of the boiler. It also helps make maintenance easy or tough. Therefore, it is vital to go for one that is suitable for the industrial setup.
Going for a 5 ton boiler means a large facility. So, before buying one, you need to have a clear idea of the plant installation area, its height, and the output requirements. Also, make sure to calculate the heat losses based on the local regulations and atmospheric pressure within the facility. Yet, the facility must be compatible with the Federal emission restriction standards.
Now given that you will be planting this boiler for the long term, it is essential to have a regular maintenance process setup. Here, the quality of the vessels matters the most, or else there will be a lot of repair work. A water treatment plant will also help you with the removal of buildups. Also, make sure the coal has a low calorific value for a minimal buildup.
Why 5 Ton/h Industrial Coal Boiler?
Here are some reasons why you should opt for a 5 ton/h industrial coal boiler:
- They are Cost Effective: The resources you need for installation are only a few. Hence, it reduces the cost of the plant to a great extent. Also, coal is less expensive as a fuel, which justifies such a massive 5 ton industrial boiler size.
- Easy to Operate: These setups use basic components for steam generation. Plus, they produce minimal to no waste, making things quite simple and convenient – even one individual can handle them.
- Better Mobility: The components are movable and have a large reuse value. This is because the installation cost is not that much in comparison.
- No Heat Waste: The ashes that come out of the system generate heat and smoke. This works best for other industrial processes. So, you are not only getting maximum benefit, but also no worries about waste disposal.
A coal steam boiler is a great source of energy generation in big industrial setups. The reason for the popularity of a 5 ton size is their cost-effective installation and massive steam production.
In order to find the right one, your opinion must not focus on the popularity of the model but on its efficiency. It is ideal that you have a clear idea of everything, from the plant area to height requirements, emission control, maintenance setups, and so on.