Steam boilers were invented in the 19th century by Steven Wilcox and George Babcock. Since their invention, not only has this amazing discovery survived but flourished. They have become a vital part of numerous societal institutions. Steam boilers are applied in various sectors such as electricity generation, agriculture, vehicle industry, brewing, production of cement, etc.
This guide will shed more light on the steam boiler cost, the factors to weigh in before buying a reliable steam boiler, and when to replace your steam boiler.
Let’s get started!
What does an industrial steam boiler cost?
As the phrase suggests, industrial steam boiler cost is the cost that comes with operating an industrial steam boiler.
An industrial steam boiler heats water to a specific temperature and releases steam, thus making it a reliable thermal energy machine. When operating the boiler, it would help if you ensured that it abides by the economic application principle to reduce cost.
For instance, huge high-capacity equipment will cost you $255 to over $300 per horsepower.
How to calculate steam boiler cost?
For many firms, the cost of steam is the median generation cost of a given production rate. The entire operating cost, like labor, power, fuel, maintenance, water, administrative heads, chemical additives, and depreciation interest, are divided by the steam produced.
How much do I pay to replace an old steam boiler?
It has been estimated that a vertical steam boiler costs around $8000 on average. However, if you want a high-end one, it will cost you about $8000. Steam boilers apply simple mechanics, thus making them reliable. All the same, they are not as quiet as most modern boilers.
When should I buy a new steam boiler?
While your steam boiler will serve you for a long time, at some point, you will need to replace it. Here are some of the signs that tell you that it needs replacing:
If you’ve had it for more than 30 years
So, how long has your steam boiler been operational? Even though many people know that their steam boiler can’t function forever, most people don’t see the essence of replacing it.
Most of the steam boilers in the market will offer you a service time of 25 to 30 years. Therefore, if your boiler has been operational for over two decades and requires significant repairs, it’s time for you to replace that old thing.
If the chain grate stoker is damaged & deformed
The steam boiler includes a chain grate to support the solid fuel inside the furnace. Besides, it is engineered to allow air towards the solid fuel for efficient combustion. If it’s broken, the air will come in massive amounts, thus leading to fast-burning and depletion of the fuel. This is one of the key part of your steam boiler cost.
Boiler drum bulge
The downstream procedure regulates steam flow in the boiler. A decrease or increase in steam flow demand will impact the pressure in the boiler drum and pipping. This will result in drum pressure, which will lead to a change in the boiling point and density of the water and steam, thus leading to boiler shrinking or swelling effect.
The sudden demand for steam increases, making the steam bubble expand beneath the water’s surface, surging the boiling point and density of the water and steam. This results in a steam drum level surge excluding the feedwater top-up.
This water level surge, steam flow rate, and reduced drum pressure lead to boiler drum bulge. This shift in pressure makes it extremely difficult to manage the steam drum level.
Pipes quantity leakage
If your steam boiler has become less functional over time, it will likely have leaks at the pipes and valve. When it leaks or needs additional make-up water, it may signify that you need a new one. By buying a new boiler, you can lessen the chances of pricey floods, vital boiler damage, or property damage.
Severe rust corrosion
This is among the most prevalent sign that you need to replace your steam boiler. Even though most modern steam boilers are designed to resist rust for a few years, broken connections and leakages will cause corrosion.
Additionally, corrosion can be caused by the chemical reaction between burners and heat exchangers. All the same, these issues can be detected through annual steam boiler checkups by experts. Again, an inspection won’t see corrosion before it begins. Still, it would be best to replace your boiler if there’s corrosion.
Unable to keep the pressure stable
If your steam boiler cannot keep the pressure stable, it’s time to replace it. This also applies to other issues, such as unresponsive controls. All operational and safety gadgets, as well as their settings, should be checked by an expert. However, if your boiler has been functioning for a long time, it would be best to replace it.
So, if you`ve seen some or most of these signs, it’s time to buy a new steam boiler.
What is the average cost of installing a new steam boiler?
Installing a new steam boiler will cost you $5700 on average. Besides, the usual range is between $3600 and $8190. A standard version, typically 80% to 90% AFUE operates at approximately $3000 to $6000. Again, high-end models cost up to $11,000.
Some of the variables that affect the cost of a steam boiler include;
1. Steam boiler design/type
The most common boiler types utilized in industrial structures are water tubes and firetube steam boilers.
Firetube steam boilers transfer hot gasses from the heat source through the tubes that pass through a water-filled shell, converting the water to steam. The firetube boilers feature a reduced capital cost and are typically easier to run. On the other hand, they have a relatively low steam capacity.
Water tube steam boilers pass water via their tubes, where they get heated by hot gases on the shell. However, they usually have increased thermal efficiencies than fire tube steam boilers. Nonetheless, they are more expensive and challenging to manufacture.
Again, these boilers are most frequently utilized to generate high-pressure steam and are vastly seen in areas that need high thermal efficiencies.
2. Boiler fuel types
The other variable that impacts the price of a steam boiler is the type of fuel your boiler uses.
Coal-fired steam boilers cost
Coal-fired steam boilers are becoming obsolete in the industry as people are opting for gas steam boilers. All the same, gas boilers are more expensive to operate compared to coal-fired boilers.
Pellet steam boiler cost
Pellet steam boilers are as reliable as they are environment-friendly. Besides, they are a cheap steam supply mechanism. Primarily they are used in schools, laundry, and factories where an inexpensive mode of heat is needed.
Gas steam boiler cost
These steam boilers use propane or natural gas and are typically more potent than standard steam boilers. The fuel is released to the boiler through external pipes linked to the boiler directly.
Heat distribution using this gas mechanism relies on its configuration. Gas systems are not quite pocket-friendly and are mainly used for industrial and low-pressure uses.
Oil boiler replacement
Typically, oil boilers are used in homes with no natural gas. Replacing an oil boiler could range from $3700 to over $7000. They function efficiently in large and small homes and offer several benefits.
3. Steam boiler working capacity
Standard capacity boilers are usually more affordable compared to high-end ones. Some boiler uses require above-average performance. Industrial applications that call for pressure or heat may be at a loss if the job is not done due to the failure of the boiler system. For this reason, you’ll need to have a high-performance boiler that can offer constant and reliable operations.
However, a standard steam boiler cost will get the job done if you need one for your home.
|Model and specification||Rated steam capacity
|Rated working pressure
|Saturated steam temperature
|Design fuel||Max transport weight
|Max transport dimension
(L x W x H)
|DZL0.5 – 1.25T||0.5||1.25||194||83||Biomass fuel||11000||3300 x 2000 x 2656|
|DZL1 – 1.25T||1||1.25||194||83||Biomass fuel||15000||5200 x 2100 x 2600|
|DZL 2 – 1.25T||2||1.25||194||83||Biomass fuel||23000||5650 x 2400 x 2700|
|DZL3 – 1.25T||3||1.25||194||83||Biomass fuel||24000||5700 x 2600 x 2800|
|DZL4 – 1.25T||4||1.25||194||83||Biomass fuel||29000||6850 x 2700 x 3200|
|DZL6 – 1.25T||6||1.25||194||83||Biomass fuel||32000||6800 x 2900 x 3400|
|DZL8 – 1.25T||8||1.25||194||83||Biomass fuel||35000||7200 x 3200 x 3800|
|DZL10 – 1.25T||10||1.25||194||83||Biomass fuel||40000||7900 x 3400 x 5500|
4. Steam boiler installation & permits cost
Typically, the installer is responsible for the fees. A boiler installation or re-installation permit will cost $66.00, which the installer should pay.
5. Regular maintenance, repair, change boiler auxiliaries’ cost
Picking a steam boiler mechanism with the least initial expense is not recommended. Most of the time, buyers discover that such boilers turn out to be the priciest in the long run.
To know the accumulative costs here’s what you need to consider;
This expense comprises the boiler’s price and accessories, which may consist of components like economizer, water softener, deaerator, and many more. What’s more, ensure to include freight work fees, offloading, and installation fees.
These charges mostly rely on the boiler’s size, whether the boiler room needs additional equipment like floor reinforcement or padding, and the related engineering expenses.
It is essential to do preventative maintenance as it affects the overall operational cost. Annual, monthly, weekly, and daily maintenance are vital in ensuring the boiler remains operational and performs effectively.
Changing boilers auxiliaries
Auxiliary boilers are the commencement point in the boiler’s system. They help clean the fluid fuels, bring the system to minimum temperatures, and heat the fuels at the recommended temperature.
Therefore, it would be best to replace them if they are damaged as they play a significant role in your steam boiler’s efficiency.
What is your steam boiler cost per ton?
The cost of steam relies on the type of fuel, steam pressure, feedwater temperature, boiler efficacy, and unit fuel price.
The price of steam is dependent on the path it goes through from the boiler to where it’s being used. Take a boiler approach and take into account the whole boiler island, including the deaeration, impact of blowdown, and parasitic steam usage.
How to improve the steam boiler cost per ton?
Improve steam boiler efficiency
Here are four ways you can improve your boiler’s efficiency:
1. Reduce stack temperature
Reducing the stack temperatures may be as simple as a 24-hour setback. This reduces the running pressure for your steam boiler and the running temperature for hydronic boilers when not in use.
2. Use an economizer
An economizer will come in handy in that it utilizes the unexploited hot flue gas to heat the water as it heads to the boiler. If you don’t have an economizer, or it’s not working, you should consider buying one or having it repaired. It saves fuel and hinders the deforming effects of cold water in the boiler.
3. Frequently tune your burner.
Inspect your steam boiler by checking the water in it and cleaning off the mud from the drums and legs. Another problem that impacts boiler efficiency is the lack of aeration. For adequate combustion of fuel in it, a specific oxygen amount is required.
If there’s inadequate air, the carbon in the fuel will get oxidized, creating carbon monoxide. This results in less heat release as the fuel are not adequately burned, thus reducing fuel utilization efficiency. Again, reduced oxygen produces soot, carbon monoxide, and smoke, which are highly hazardous. Check to follow Industrial Gas Burner.
4. Use a Variable Frequency Drive
Most of the pumps or burner fans don’t have VFDs. Nevertheless, it would be best to install it if your boiler doesn’t have it. Thanks to the affinity law for fans and pumps concept, it leads to significant savings.
If your boiler has a circulation pump or fan regulated by a valve or dumper, it wastes electricity little by little. This is where a VFD comes in handy, as it allows the system to control the flow with pump or fan speed.
Coal-fired steam boiler efficiency
Boiler effectiveness mostly depends on the losses in the mechanism. In high-end coal-fired boilers, the losses account for approximately 12 – 14%. About 50% of these losses are controlled by fuel properties, including surrounding air conditions, hydrogen, and moisture in the fuels. The rests are dry gas and carbon losses.
The most reliable efficiency in a coal-fired steam boiler can be attained if the losses are not as much. Half of the losses rely on the surrounding air and fuel, so effectiveness can be reached by adequately tuning the remaining 50%; dry gas and carbon losses.
Steam boiler design
Flue gas temperature can be decreased using an adequately designed economizer to 170F. Usually, every 40F decrease in flue gas temp surges your boiler’s effectiveness by 1%.
The most suitable boiler system may integrate various small boilers to manage the load as opposed to having one large one. Several smaller boilers come with a handful of upsides than one massive unit.
The turndown can be more significant as the smallest boiler’s turndown in the system governs the turndown of the entire system’s capacity. Additionally, several small boilers provide improved reliability over one large unit because if one small unit shuts down, the rest will continue working.
Boiler auxiliary increase steam boiler efficiency
Typically, the boiler is the entire system’s heart; thus, heat production will stop instantly if it fails. Therefore, if you need steam, it is vital that your boiler and all the auxiliary parts remain in perfect working condition as this lets the system run efficiently and safely.
A high-efficiency steam boiler cost
Typically, high-efficiency steam boilers are expensive to install. Their installation price stands at between $6000 to $11000. These are usually used in factories and other institutions that require a lot of steam.
Steam boiler cost per ton
It is essential to know the cost of steam, and they all come in handy in improving your boiler`s efficiency. For instance, steam boiler cost per ton works as a basis for optimizing the process of steam generation and reducing cost.
Yongxing steam heating cost very effective
Here you can find 1.0Mpa, 0.7Mpa, and 0.4Mpa, low and medium-voltage steam boilers in terms of pressure. Again, if you require an industrial steam boiler, you can find the WDR0.24-2.8MW/0.3-4T or LDR0.12-0.7MW/0.1-1T. Nevertheless, if you need something larger or customized, you can contact our engineers. WDR and LDR electric steam boiler cost is a little higher in investment.
How long does your steam boiler last?
The larger the investment, the longer the boiler life. In addition, you pay a higher steam boiler cost, which will require more high-quality boiler auxiliaries. You could get a steam boiler’s life expectancy is 25 to 30 years if maintained and taken care of properly.
How much does your steam boiler installation cost?
The average price of installing a steam boiler is roughly $5700 though labor fees usually range from $1000 or more. On the other hand, re-installation cost is almost the same as installing a new steam boiler, about $4000 for an average boiler and $8000 for a high-end boiler.
These charges do not cover the installation of pipes and other equipment, the foundation work, and the cost of the valves. Again, to adequately design your boiler room, you`ll need to consult the installer, who will offer you a quotation as per your needs.
When it comes to post-maintenance charges, these are not included in the installation fees. They will be separate and charged every time you call for your boiler’s maintenance.
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