How to select an industrial steam boiler? - Atlas Copco USA

There are many types of industrial steam boilers. How to know which one is the best for your needs? This guide explains the different types of boilers; that each have their own features and benefits.

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Industrial steam boilers are used to transport heat energy from one location to another in your facility. The boiler is a pressure vessel that allows heat to be captured and efficiently carried from the boiler room to the point of use. However, due to the inherent dangers of a steam boiler operation there are strict rules and regulations for both the manufacturing and operation of these pieces of equipment.

To put it simply, boilers are internally fired heat exchangers to export steam or hot water. 

In a firetube steam boiler, the hot gases from combustion flow through tubes to transfer heat into the water contained in the pressure vessel. Firetube boilers are often used at smaller industrial facilities with lower operating pressures. These types of boilers offer a cost-efficient and robust heating solution. Compared to a watertube steam boiler, a typical firetube boiler has a simple design, requiring minimal maintenance.

An electric steam boiler is driven by electrical energy. Unlike other boilers, industrial electric boilers do not transfer combustion energy.  Their design utilizes both the vertical and horizontal boiler shell orientation.  Electric steam boilers can be configured for both steam and hot water applications.  Next to extreme high turndown, zero emissions; another advantage is thermal shock resistivity. 

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However at high capacity electric steam boilers require massive amounts of installed electric power.  Available power is today the restricting factor for this technology.  There is however a continuous push for innovation that may soon lead to a sustainable electric steam boiler that can provide steam or hot water at high capacities.

Condensing steam boilers are quickly becoming the go-to boilers in both industrial and residential markets. Due to the relatively low temperature of hot water loops in homes and small industrial applications, a condensing hot water boiler reaches efficiency levels (90% or higher) other standard boilers cannot achieve. Condensing steam boilers feature a specially designed heat exchanger that lowers the flue gas temperature enough to condense.  This condensation process generates extra energy that is captured and reused.

There are several factors to consider.  Obviously you start from the required output you need, the preferred efficiency levels.  Each proposal also has a specific investment cost.

In order to make the best decision, make sure to also considering the long-term impact of an industrial steam boiler on your operation. 

• How much steam is currently used by your facility?
• What output type is required of the boiler? (i.e. high pressure steam, low pressure steam, superheated steam, hydronic hot water, domestic hot water)
• What pressures and temperatures should the boiler operate at?
• What is the desired efficiency of the boiler?
• Which fuel will be used to fire the burner? (i.e. NG, oil, propane, biofuel)
• Where will the boiler be installed?
• Is the boiler easily accessible or hard to reach?
• Does the weather vary significantly throughout the year? (i.e. humidity, temperature, etc.)

Boilers are used throughout the world to produce steam or hot water. Nearly every manufacturing sector utilizes a boiler in their process to produce the most basic items we rely on every day, including food, oil, paper and durable goods. When selecting a boiler, many factors must be considered. Do you need a temporary or permanent solution? What is the capacity demand? Do you need steam, or hot water heating? What type of boiler is best for your process? What other equipment do you need to support your boiler? The list goes on.

Nationwide Boiler has put together a guide to help you choose which boiler is best for you. The list below will help lead you to make an informed decision suitable for your specific boiler application.

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