Have you been considering industrial condensing gas boilers for a while now but can’t make up your mind? We’ve got you! The industrial condensing steam boiler has been in demand due to its highest efficiency. It can substantially cut your energy bills and reduce your carbon footprint. Yet, there’s a lot you need to know before you can jump to a conclusion.
In the article below, you will get details regarding industrial condensing gas boilers, including their working, efficiency, lifespan, and more. You’ll also learn about the best industrial condensing gas boiler available so that you can make an informed decision. Without further ado, let’s get into it.
Industrial Condensing Gas Boiler: Working and Diagram
Working on condensing Gas Boilers
The main question that comes to mind is: “How does an industrial condensing gas boiler work and how to choose condensing steam boiler?” A condensing boiler uses condensing technology to use heat efficiently. It burns fuel to produce heat, which moves to the radiators to provide heat to the system.
Moreover, they produce less carbon monoxide and nitrogen oxide, thus reducing emissions from your factory.
The main feature that makes it stand out from non-condensing boilers is that these radiators capture heat from waste gases produced from burning. They have more extensive heat exchange surfaces to convert more heat from the boiler’s burner into useful heat.
Meanwhile, they can use this energy to warm the water once it circulates through the central system. Hence, less energy is required to start the heating process. This shows how an industrial condensing gas boiler can use less energy while producing the same output, making it more efficient.
Condensing Boiler Diagram
The diagram below shows all the parts of a typical condenser boiler and explains their operation. A heat exchanger helps heat the water and cool the waste gases created during fuel burning.
The outdoor pipe expels such gases (also known as a flue). The latent heat energy the gases contain is released through condensation while cooling. Your boiler then uses this heat energy to continue running your central heating.
Condensing Boilers: Pros and Cons
Industrial condensing gas boilers offer several benefits, such as a reduced carbon footprint and increased efficiency. However, there are also some disadvantages that you need to know. Let’s compare condensing boilers’ pros and cons and see if they are worth your money.
Advantages of Condensing Boilers
Here are the three main disadvantages of condensing boilers:
1. Latent Heat Recovery
Latent heat recovery, which raises thermal efficiency, is the main advantage of condensing boilers. The boiler’s fuel has a 50% moisture content. During condensation, the heat exchanger recovers the latent heat of this moisture. In contrast to the fuel’s lower heat value, this results in more than 100% efficiency.
2. Reduced Emissions
A condensing boiler uses a flue gas condenser, which lowers flue gas emissions. The condensate creates a layer that traps large particles such as sulphuric acid and chlorides. This results in the reduction of harmful emissions, including carbon dioxide and nitrogen oxide. What’s shocking is that installing a condensing boiler can reduce your carbon footprint by up to 1200 kg.
3. Low Energy Bills
To prevent losing heat, condensing boilers warm cold water before it enters the system. The units can maximize their efficiency. As a result, the boiler will use less fuel, and the expenses will be lower compared to other industrial gas boilers
4. Space Savings
A condensing boiler doesn’t require a hot water tank. Hence, installing in small spaces is considerably easier. It’s best when your boiler room has limited space.
Disadvantages of Condensing Boilers
Let’s throw some light on the three main disadvantages of an industrial condensing gas boiler.
1. High Maintenance Cost
Condensing boilers are more complicated and require gas-safe licensed professionals, which increases boiler prices. Non-condensing boilers can be repaired cheaply, saving you money in the short term. Condensing boilers, however, save you money in the long run.
2. Corrosive
Combustion products can cause corrosion, especially when mechanical strain is high. This results in cracks in heat exchangers made of low-temperature steel. Yet, a few things can make this corrosion less severe. For example, using corrosion-resistant materials, performing careful installation, and utilizing high-tech controls
3. More Complex
If their external pipes freeze, these condensing boilers may stop working in cold weather. They can also corrode as a result of the acid concentration. However, proper maintenance can eliminate these risks.
Industrial Condensing Gas Boiler: What You Must Know
There are tons of things you need to know about an industrial condensing gas boiler. Let’s get started with the basics.
Condensing vs. Combi Boiler: Are They the Same?
One common question is, “Is a condensing boiler the same as a combi boiler?” The short answer is no. As discussed earlier, a condensing boiler refers to the technology it uses to boost efficiency. On the other hand, a combi (or combination) boiler requires no storage tanks.
It is interesting to note that you will need a condensing boiler to install combi boilers. Even so, condensing boilers aren’t necessarily combi boilers. They can be conventional boilers or system boilers.
Condensing vs Non-Condensing Boilers
In comparison to a non-condensing boiler, an industrial condensing gas boiler is much more efficient. Modern boilers are capable of 90% efficiency or even above. Without condensing technology, this efficiency was only 70–80%.
A condensing boiler uses a flue gas recovery system, which makes it more efficient. The cold water that enters the boiler is heated using the waste heat in the flue. This way, condensing boilers use less fuel while producing the same output. Thus, they aren’t just more efficient but also more eco-friendly.
Let’s look at the table to understand the difference between condensing and non-condensing boilers.
| Condensing Boilers | Non-Condensing Boiler | |
| Heat Exchanger | One or more with a large surface area | One with a small area |
| Energy efficiency | 78% | Up to 99% |
| Annual Carbon Emission | 5.2 tonnes CO2 | 7.95 tonnes CO2 |
| Cost efficiency | High initial cost, less efficient in the long run | Low initial cost, more efficient in the long run |
| Combustion Temperature | 50-60 ℃ | 120-180 C |
Industrial Condensing Gas Boiler Efficiency
The efficiency of a condensing boiler is measured by its annual fuel utilization efficiency (AFUE). Here, an AFUE of 90% means that 10% of energy is lost while the remaining 90% becomes heat for your industry. In general, the higher efficiency condensing boiler you have, the greater the savings.
Generally, an industrial condensing gas boiler is 12% more efficient than a non-condensing one. This is because condensing boilers use 30% of the heat, while non-condensing boilers let it go to waste. As mentioned earlier, these boilers use a “flue gas heat recovery system“’ to recycle the heat. The recycled heat then heats the cold water, increasing the efficiency to 99%.
Additionally, condensing boilers have the highest calorific potential regarding heating output.
In contrast, conventional boilers deliver the lowest calorific value. Hence, condensation boosts the condensing boiler’s efficiency by 10% to 15%.
Need for Hot Water Tank With a Condensing Boiler
Another confusion you may face is, ”Do I need a hot water tank with an industrial condensing gas boiler?” In simple terms, no. Condensing boilers don’t need a hot water tank. Yet, the answer depends on the type of boiler you are talking about. Combi boilers don’t require a hot water tank. In comparison, system boilers or heat-only boilers do.
In contrast to the system and heat-only boilers, which use tanks to store hot water, a combi boiler heats and supplies water when required.
Installation of an industrial condensing gas boiler; is it complicated?
The installation of a condensing boiler isn’t very complex. The only difference between a condensing boiler and a non-condensing one is the requirement for a condensate drain. If you have a skilled installer, finding a good position for the drain and installing a plastic overflow pipe won’t be an issue.
Best Condensing Boilers
There are various factors to consider before deciding which boiler is the best. These include cost, efficiency, and capacity. An industrial boiler has at least 70kW of gas input. Keeping these things in mind, let’s discuss the condensing boiler prices.
Condensing Boiler Prices
An industrial condensing gas boiler with a steam production rate of 4 t/h can cost you $500–7000. While a boiler with 60 t/h steam production can cost $6000–$30,000, Higher-capacity condensing boilers can reach $100,000 or even more.
Best Industrial Condensing Boiler Manufacturers and Specifications
You don’t want to overwhelm yourself with a long list of condensing boilers. Do you? Therefore, we narrowed it down to one condensing steam boiler that outshines the other boilers in the market. Let’s discuss why it’s the best.
Specifications
- One-piece, horizontal design to reduce space.
- A larger chamber heats up more quickly yet requires less energy.
- Threaded flue pipe threaded with a wave-shaped furnace to enhance heat transfer and save fuel.
- Engineered safety features, such as an explosion-proof door, provide constant safety.
- LCD monitor to track how the boiler is doing
- Freedom to connect many boilers and calculate each load individually.
- Condensing waste heat recovery technology to achieve optimal energy utilization.
Verdict
An industrial condensing gas boiler has been in demand recently. Mainly because of its high efficiency and reduced carbon footprint. Yet, these aren’t the only features it offers. It lowers your energy bills and saves space. Unfortunately, there are a few disadvantages to a condensing gas boiler. One of them is corrosion.
The best part is you can always lessen their effects with careful purchase and timely service. To ensure you get the best deal, buy from reputable suppliers. Our company offers the most affordable prices and after-sale services to ensure hassle-free installation. So what are you waiting for? Grab the offer now!