Steam boiler

Exploring the Steam Boiler Market Dynamics

Market Overview: The global steam boiler market is on a robust growth trajectory, with an estimated value of $17.4 billion in 2023 and a projected increase to $23.3 billion by 2030, reflecting a compound annual growth rate (CAGR) of 4.3% during this period, according to Global Industry Analysts, Inc. Notably, the Water Tube Boilers segment is expected to lead this growth, reaching approximately $15.8 billion by 2030, with a CAGR of 4.7%. Meanwhile, the Fire Tube Boilers segment is also set for expansion, albeit at a slightly lower growth rate of 3.3%. Insights into regional markets reveal that the U.S. steam boiler market was valued at $4.7 billion in 2023, while China is projected to experience a remarkable growth rate of 7.0% CAGR, aiming for a market value of $4.9 billion by 2030.

Industry Insights: The steam boiler industry is increasingly influenced by advancements in technology and shifting consumer preferences towards energy efficiency and sustainability. As industries seek to enhance operational efficiency, the demand for modern steam boiler systems, particularly those utilizing water tube technology, is surging. This trend is further supported by the growing emphasis on reducing carbon footprints, which is driving investments in innovative boiler solutions. Additionally, market players are focusing on strategic collaborations and technological innovations to gain a competitive edge. Major companies in the sector are adapting to these changes by enhancing product offerings and exploring niche markets, thereby positioning themselves effectively in this evolving landscape. The integration of smart technologies in steam boiler systems is expected to further shape consumer behavior, as businesses prioritize reliability and energy efficiency in their purchasing decisions.

Types of steam boilers

A steam boiler is a large machine that produces steam by heating water. Big industrial facilities and some small businesses use them. It transfers heat from the burning fuel into the water until it becomes steam. The fuel used may be natural gas, propane, coal, oil, or wood.

There are two major types of steam boilers: fire-tube and water-tube boilers.

• A fire-tube boiler has a series of tubes. Hot gas from the fire goes through the tubes. The heat from the gas warms the water that's outside the tubes, turning it into steam. The steam leaves through a vent or pipe. Fire-tube boilers are smaller and cost less to make than water-tube boilers.
• A water-tube boiler works differently. Water travels through small pipes called tubes. Hot gas from the fire heats the tubes. The tubing is often made of steel or alloy. When the water inside the tubes gets heated by the hot gas, it changes into steam. This type of boiler is built more massive and is suitable for high-producing demands.

Another way to categorize steam boilers is based on pressure. Low-pressure steam boilers operate at lower pressure and are suitable for heating applications. High-pressure steam boilers generate steam at higher pressure levels and are used in power generation and industrial processes. Dual-pressure boilers can operate at both low and high-pressure levels.

The fuel type also differentiates steam boilers. Gas steam boilers burn natural gas or propane and are considered eco-friendly. Diesel fuel boilers use heating oil, and solid fuel boilers burn coal or biomass are commonly used in areas without access to gas. There are also electric boilers that use electricity to generate heat.

Specifications & maintenance of steam boilers

Specifications

• Capacity:

  The performance of a steam boiler is measured in two ways: output and steaming ability. The output shows how much steam the boiler can produce per unit of time. Common outputs range from several hundred kilograms to several tons per hour. The capacity shows the size of the boiler's generating ability and is usually reflected in the horsepower (HP) of the boiler.

• Pressure:

  Boiler steam pressure is the pressure at which the boiler operates and is usually expressed in bar or MPa. Pressure influences the temperature of the steam produced by the boiler and the energy it can provide. Common pressure ranges are between 0.7 to 1.25 MPa.

• Fuel type:

  Steam boilers can be divided into different types according to fuel types, such as natural gas, oil, coal, biomass, electricity, etc. The design and combustion system of the boiler are different depending on the fuel type to ensure efficient fuel combustion and steam generation.

• Efficiency:

  The efficiency of a steam boiler represents the conversion of fuel energy into steam energy, which shows the energy utilization of the boiler. Boiler efficiency is usually expressed as thermal efficiency, which is the ratio of the useful energy produced to the energy consumed by fuel combustion. Higher efficiency means that the boiler can produce more steam per unit of fuel.

Maintenance

• Regular inspections:

  At specified intervals, the equipment should be checked thoroughly, including appearance, fittings, and control. Inspection records should be established, and any abnormalities should be reported and dealt with immediately.

• Water treatment:

  Ensure the quality of water used in the steam boiler is good. Use suitable water treatment agents to avoid problems such as scale and corrosion. Regularly monitor water quality and adjust treatment plans as necessary.

• Combustion system maintenance:

  Ensure efficient combustion by regularly cleaning the burner and adjusting the air-fuel ratio. Check for leaks in the combustion system and repair any faulty parts in a timely manner.

• Regular cleaning and descaling:

  Regularly clean the boiler's heat exchanger and pipes to remove deposits and impurities. Consider adding a descaling agent to the water to reduce scale buildup. Establish a cleaning and descaling schedule based on water quality and usage.

• Safety device check:

  Regularly check the safety devices of the steam boiler, such as pressure relief valves, low-water shutdown, etc. Ensure that these devices work correctly and are within the prescribed parameters. Make necessary adjustments and repairs as required.

Applications of Industrial Steam Boiler

Industrial steam boilers are a critical component of many industries. Here are some of the most common applications of an industrial steam boiler:

• Power Generation: High-capacity steam boilers are used to generate power in a process known as steam turbine generation. The steam turbine generator works by using high-pressure steam to drive a turbine connected to an electrical generator. The turbine's rotation, powered by the steam's energy, directly spins the generator, converting the steam's thermal energy into electrical energy.
• Food Processing: The food processing industry uses steam boilers to sanitize equipment and cook food. Bakeries use steam boilers in ovens to ensure proper moisture levels and cook products efficiently. The boiler also helps to preserve food by creating a low-oxygen environment, preventing bacteria growth. In the meat industry, steam sterilizes carcasses, cutting tools, and other equipment to ensure proper hygiene.
• Textile Industry: Steam boilers are used to manufacture textiles, such as cotton, wool, linen, polyester, and other fabrics. Steam is injected into fiber and yarn to relax and remove wrinkles. Steam also raises the temperature in textile factories, speeding up the dyeing and finishing process.
• Healthcare: Hospitals and healthcare facilities use industrial steam boilers to sterilize equipment, linens, and surgical instruments. High-pressure steam sterilization helps eliminate harmful pathogens, ensuring a sterile environment for medical procedures and patient care.
• Chemical Industry: The chemical industry uses steam boilers for various processes, such as distillation, fermentation, and drying. The high-temperature steam regulates boiler temperature, facilitates chemical reactions, and provides heating for different production processes.
• Pulp and Paper Production: Steam boilers are an integral part of pulp and paper production. They provide the steam required for cooking pulp, drying paper sheets, and powering turbines for electricity generation. The boilers help maintain the necessary temperature and pressure levels for efficient production.
• Hospitality and Restaurants: Hotels, resorts, and restaurants use steam boilers for cooking, food, and laundry. Steam boilers power hotel kitchen equipment such as steamers, ovens, and combi ovens. In restaurants, they are used to prepare vegetables, meats, and seafood. The laundry facility will also use the steam boiler to sanitize linens and towels.

How to choose

• Scale

  Understanding the scale of operations is crucial before deciding on the type of steam boiler to invest in. A small production facility may only require a low-pressure steam boiler, meaning one with a pressure of less than 15 psi. It will suffice for tasks like commercial space heating and hot-water heating. On the other hand, large-scale industrial facilities, such as paper and pulp industries, food processing, textile companies, refineries, or chemical plants, will require high-pressure steam boilers. They need a constant supply of energy at a higher intensity.

• Fuel source

  The fuel source available to a business will also determine the type of steam boiler to invest in. While natural gas and diesel remain common fuel sources, other options include biomass, coal, heavy oil, electric, and propane. Biomass is an ever-popular choice across the globe due to its renewability. It includes wood pellets, crop residues, and dedicated energy crops. Businesses with access to efficient natural gas pipelines will have smooth, cost-effective operations. If a company is situated far away from natural gas pipelines, using diesel stored in tanks will work. Companies that struggle with electricity costs will have better options with coal as a primary fuel. Only certain industrial settings can burn high-sulfur coal, so one needs to check the capability of the equipment and local regulations first. Heavy oil, like bunker C, is used in hydraulic machinery and incinerators. Some industries, like chemical plants, have smooth operations using propane. Electric steam boilers work in facilities looking for affordable and environmentally-friendly options.

• Efficiency

  Choose a boiler with a good thermal efficiency percentage. This is the percentage of fuel energy converted into heat energy. Steam boilers that recycle waste heat from flue gas through heat exchangers are called condensing boilers. They can achieve efficiency levels between 90% and 98%.

• Replacement parts

  Check for availability of replacement parts. Discuss how long the supplier expects to support the product and whether critical parts will be readily available.

Steam boiler FAQ

Q1: What is the life expectancy of a steam boiler?

A1: Typically, industrial steam boilers can last anywhere from 15 years to 30 years or more if they are well-designed and maintained properly.

Q2: What causes steam boiler failure?

A2: Steam boilers fail for a number of reasons, the most common being improper maintenance. Other causes include corrosion, water treatment problems, equipment defects, operational error and boiler overload.

Q3: What is boiler efficiency?

A3: Boiler efficiency is the measure of how effectively a steam boiler converts the energy in fuel to usable energy in the form of steam. It is expressed as a percentage. High efficiency boilers result in lower operating costs and reduced environmental impact.

Q4: How can the efficiency of a steam boiler be improved?

A4: The efficiency of a steam boiler can be improved by utilising economisers or combined heat and power systems, maintaining optimal combustion, ensuring proper insulation, using low-quality fuel and regular boiler maintenance.

Q5: What are the safety considerations for steam boilers?

A5: The safety considerations for steam boilers include regular maintenance and inspections, proper water treatment, installation of safety valves and pressure controls, adherence to regulations and guidelines, and providing training to operators.