Wondering how industrial water boilers work and how they can benefit your business? Look no further! In this comprehensive article, we’ll explain everything you need to know about an industrial water boiler. This will include its efficient operating principle to the various types available.
Furthermore, you’ll discover the advantages of hot water boilers, including lower costs and higher system efficiency. We’ll also explore their diverse applications in sterilization and industrial water heating.
Let’s delve into the world of industrial water boilers and transform how you heat your facility. Your efficient and cost-effective future awaits, so let’s get started!
Industrial Water Boiler System; What Is It and How Does it Work?
Industrial Hot Water Boiler System
Simply put, a hot water boiler system heats the water. It can be used to heat water for industrial or domestic purposes. The boiler heats the water using electricity, gas, or oil before it’s piped to the location where it is needed.
Since hot water boiler systems have a small storage tank, they frequently work with tankless water heaters. This gives the gas burner ample time to restart before the next hot water demand. This combination makes hot water available without needing much-heated water in reserve.
How Does Hot Water Boiler Work?
Industrial hot water boilers are built like steam boilers. However, they work with a water level and steam space rather than being partially filled with water.
A burner is fired into the boiler’s furnace and tubes to heat the water inside the boiler shell. With the help of a circulating pump and pipes, hot water is fed into the process and then returned to the boiler to be heated further. Here, to prevent corrosion, any water loss must be made up for by chemically treated fresh water.
Moreover, the boiler pressure vessel is usually a horizontal, closed, cylindrical tube lined with insulation. The most typical industrial hot water boilers have two or three passes. Each pass consists of a unique system of pipes through which the hot flue gas passes before turning inside the boiler.
Industrial Water Tube Boiler Types
Let’s dive deeper by shedding light on the types of water boilers available.
1. High-Temperature Hot Water Boilers (HTHW)
It’s a boiler with a maximum temperature higher than 350°F. The typical maximum operating pressure for an HTHW system is less than 300 PSIG. These systems are perfect for larger systems, such as district and campus heating. This is because they have large sizes, high heat loads, and vast piping networks. Also, large process applications are perfect for these systems due to the high-temperature requirements that other boilers can’t meet.
2. Medium-Temperature Hot Water Boilers (MTHW)
It’s a boiler with a temperature between 250°F and 350°F and a maximum operating pressure of 150 PSIG. Systems that make use of this boiler include campus and district energy loops. Besides, flat and hotel complexes and minor processes also use these boilers.
3. Low-Temperature Hot Water Boilers (LTHW)
It’s the system offering temperatures lower than 250°F. The maximum operating pressure for an LTHW system is less than 30 PSIG. These boilers are frequently employed in smaller structures, including houses. Radiators are used in buildings with LTHW to transfer heat to various spaces.
Advantages of Industrial Water Boiler
As an industrialist, your main goal is to increase boiler efficiency while reducing operating costs. Like fire tube boiler, an industrial water boiler provides you with that! The benefits are as follows:
1. Lower Initial Equipment Costs
HTHW boilers have a simpler design and require fewer boiler room components. This results in lower upfront investment costs when setting up the system. Also, it’s an easy system to install and maintain compared to others.
2. Lower Operating Costs
HTHW boilers eliminate losses associated with steam boilers. These include steam traps, leaks, vents, and blowdowns. This helps reduce ongoing operating expenses. Moreover, they are less affected by temperature and pressure drops, which saves operational costs.
3. Higher System Efficiency
HTHW systems efficiently handle high load spikes due to their large heat storage of boiler capacity. This means the burner operates more evenly and effectively. Thus resulting in higher overall system efficiency and reduced energy consumption.
4. Elevation Changes Don’t Affect System
Unlike steam systems, HTHW boilers use circulation pumps, which overcome total system losses. This means that elevation differences have little impact on the system’s performance. This makes it a more versatile and reliable heating solution.
Industrial Water Boiler Applications
Various industries employ industrial commercial hot water boiler systems to make heating easier. Some of them include:
The high temperature of hot water destroys bacteria, making it efficient for sterilizing hard surfaces. The following facilities use hot water to sterilize hard surfaces:
- Food processing facilities
- Sections of general industry where it is required to clean the facility, equipment, counters, floors, etc.
2. Industrial Water Heating
Heated water is used in various industrial processes, such as mixing, curing, and cleaning. This makes it easier to manufacture products and maintain a sterile manufacturing environment. Facilities that make use of hot water include:
- Facilities for cleaning bottles
- Vehicles and truck washes
- Construction sites
- Gypsum plants
- Facilities with high volumes, such as hotels and hospitals.
What Fuels Does an Industrial Water Boiler Use?
There are different fuels a boiler can use. Let’s look at them individually.
Due to its efficiency and cleanliness, gas is the most popular fuel for a hot water boiler. Additionally, it generates less waste than other fuels, sometimes called “dirty” energy sources. Hence, gas is the preferred fuel for boilers.
To use oil for your hot water boiler, you will need to have it pumped into your oil tank or delivered by tanker truck. This makes it a pricey alternative. Also, you’ll need regular upkeep and inspections because leaks can result in significant damage if not discovered in time.
You can use electricity instead of alternative fuels like wood or coal, which require a lot of labor. There’s no need to store or handle fossil fuels. Additionally, using electricity requires less maintenance than using oil or gas. This makes it a popular choice for those seeking a hassle-free heating solution.
How Long Does Industrial Water Boiler Last?
For industrial hot water boilers, the typical lifespan of a heating system is around 10–20 years. However, this can vary, with some boilers lasting up to 15 years while others may only last five years. To ensure your boiler stays in good shape and avoid heating issues, watch out for these signs:
1. Water Leaks
Check for leaks from the bottom of the unit or where pipes connect to it. Any leaks should be addressed promptly to prevent further damage.
2. Insufficient Hot Water
If your facility requires a high volume of hot water and the boiler struggles to keep up, it might be a sign that it needs replacement or upgrades.
3. Wear and Tear:
Hot water boilers have a few moving parts. However, if there’s wear and tear, consider replacing it with energy-efficient tankless units. They require less maintenance and offer long-term cost savings.
By monitoring and addressing any issues, you can ensure the reliable operation of your industrial hot water boiler.
Difference Between Steam Boilers and Hot Water Boiler Systems
There are two categories for steam boilers: one using > 15 PSIG and the other using <15 PSIG. Their Maximum Allowable Working Pressure (MAWP) design determines this pressure. Furthermore, a heating boiler may be regarded as a hot water boiler if it offers a MAWP of less than 160 PSIG and a maximum temperature of 250°F.
Last, there are different uses for hot water boiler systems and steam boilers. A steam boiler is more appropriate for humidification, direct injection, and heat exchangers. In contrast, an HTHW boiler is more suited for district and campus heating.
Hot Water Boiler Price
The cost of an industrial water boiler depends on its size and features. You can get a new 1000 kw hot water boiler with a warranty of 20 years for $10,000 to $30,000. Yet, it can save you money in the long run because you won’t need to pay much for repairs or replacements.
The cost of a new boiler will vary depending on its size, features, and charges like installation. Purchasing an energy-efficient model that consumes less gas or electricity is one way to save money. If you purchase one with efficiency features, you can also be eligible for a tax credit from your state government.
Industrial water boiler offers features and benefits you won’t find in many other boilers. To begin with, you can choose between three different types of boilers to suit your needs. The best part is that the boiler offers lower prices with lower operating costs.
It provides higher energy efficiency and doesn’t produce any pollutants. If purchased from the right place, an industrial water boiler offers long life spans. All these factors, when combined, can make your business more profitable and hassle-free.
So, take advantage of this chance to supercharge your business! Contact us today and embark on a greener, more efficient future with our cutting-edge industrial water boilers. The power to revolutionize your heating system awaits; let’s get started!