The Advantages of Steam Generators Over Steam Boilers

Electric steam generator and steam boilers are two popular technologies that seem comparable when looking for a steam source option for your company. Despite the fact that they both generate steam for a range of applications, the two systems differ greatly, particularly in how they function. You may choose the best system for your process requirements by being aware of these distinctions and the two systems’ designs.

team Generator: What Is It?

A quicker and more compact substitute for steam boilers are steam generators. Their design for heating water and turning it into steam is really straightforward. A steam generator’s single stainless steel tube coil receives a steady supply of water from feedwater pumps in order to run. The water is exposed to the heat from hot gases outside the coil as it moves through the generator in the metal coil. After then, the feedwater gets hotter and hotter until it turns into steam and leaves the vessel by a single outlet. There are several industrial and commercial uses for the steam after that.

The majority of steam generators are once-through, forced-flow devices with a single coil. Excess water that does not turn into steam is collected in a filter for disposal or reuse, and surplus gases can pass through the generator for convenient release. For modest to moderate levels of steam generation, the design makes the steam generator straightforward and easy to use.

A Steam Boiler: What Is It?

Although they function on a much bigger scale (and hence have a more complex design), steam boilers are comparable to steam generators. They are employed in sizable commercial or industrial settings when a higher steam output is required than the majority of steam generators can supply. They can boil water at subcritical temperatures and turn it into steam because to their sophisticated fuel system and pressure vessels that can tolerate high pressure levels.

Some buildings need a qualified operator to be present at all times the boilers are operating due to the complexity of the systems, the huge quantities of hot steam they produce, and the potentially hazardous pressure levels at which they operate. These people need to be certified in safety, operating standards, and emergency and malfunction response techniques.

Steam boilers come in two primary varieties:

Boilers in firetubes

A big water tank with several pipes passing through it is a feature of firetube boilers. Additionally, the boiler has a sizable fire that burns fuel rapidly to raise the temperature of the gases passing through the pipes to extremely high levels. After entering the storage tank through the pipes, this heat causes the water to boil, turn into steam, and ascend to the top of the tank. The steam can then be used as energy for construction or industrial activities by the connected systems.

Boilers in water tubes

A more recent alternative to conventional firetube designs, watertube boilers are essentially the reverse of firetube boilers. In contrast to firetube boilers, which use a reservoir of water and send hot gasses down the tubes, watertube boilers use pipes to carry water from a reservoir. The boiler’s body has many pipe lengths that are continuously filled with water. All of the tubes are encircled by hot gas that has been heated by a fire; heat moves through the tube to cause the water to boil and produce steam. The still-liquid water returns to the reservoir before being sent back through the pipes for heating and conversion, while the steam ascends to the top of the pipes.

Steam Generator Advantages

Compared to steam boilers, steam generators are smaller, simpler to build, and possibly less hazardous. Among the particular benefits they offer are:

Compact design: A steam generator is easy to set up and start because to its compact size and straightforward design. For on-demand or emergency steam generation, this is perfect.

Operational ease: Because of their simplicity, facilities are better equipped to handle maintenance and operational duties. Additionally, they don’t need a qualified and licensed operator to be present on the property.

Cost-effectiveness: Compared to steam boilers, steam generators are less expensive initially and require less maintenance and personnel.

Efficiency: With an electrical energy to heat conversion rate of almost 100%, steam generators are exceptionally energy-efficient.

Steam generators may be the best option for on-demand steam systems, emergencies, and minor commercial steam needs.

A Few Benefits of Steam Boilers

Compared to steam generators, steam boilers are bigger and more potent. They benefit from this in a number of ways, including the following:

Increased capacity to produce steam: Both varieties of steam boilers are bigger, stronger, and more able to generate enormous amounts of steam.

Dynamic steam generation: Throughout work cycles, steam boilers may adapt to changing needs for steam by swiftly switching to generating less steam when less is required and producing more during busy cycles.

Can constantly meet high needs for steam: Steam boilers can continually satisfy high demands for steam once they achieve optimal production levels.

Why Choose a Steam Generator Instead of a Steam Boiler?

A huge boiler is not necessary for many smaller steam-based activities. An readily transportable steam generator would be the ideal instrument for such minor operations. Here are some of the main justifications for switching from a fuel-fired steam boiler to an electric steam generator:

Safety: Since electric steam generators don’t use flammable fuel, they are less likely to experience significant malfunctions than fuel-fired boilers. Low temperatures, inadequate water treatment, incorrect warm-up, drawing a vacuum, flame impingement, extreme overfiring, and even outright explosions can all cause boilers that burn fossil fuels to fail.

Portability: Because of its compact form, steam generators may be utilized in spaces with limited capacity. Small-scale generators from Ekotekkazan are transportable and don’t need lengthy steam lines or boiler chambers for significant installation.

Energy efficiency: When not in use, electric steam generators use no energy. They only cycle when steam is required when they are operating. In warmer months, when full power might not be required, this is especially useful. Because of their huge size and intricate piping system, fuel-fired boilers are far more energy-intensive to operate at full capacity and burn fuel continuously, even when no steam is needed.

Fast start: Unlike boilers, which can take hours to reach rated output from a cold start, steam generators can reach rated output in only a few minutes due to their small size, single chamber, and very low water consumption. A steam generator’s quick-start feature makes it perfect for emergencies and situations like pilot plants, labs, and process testing when steam may not be required for extended periods of time.

Cost: Setting up a steam boiler system at your establishment can be expensive and time-consuming. Applications that don’t need large amounts of steam, like those produced by boilers, could benefit more from steam generators since they are significantly less expensive than a full-scale fuel-fired boiler system.