A steam generator, commonly referred to as a boiler, is a mechanical device designed to heat water into either hot water or steam using heat from fuel or other energy sources. The term "boiler" originally referred to the container where water was heated over fire, while "furnace" denotes the area where fuel is burned. Together, they form the two main components of a boiler system.
According to the "Special Equipment Safety Supervision Regulations," any device with a volume of 30 liters or more is classified as a boiler. Most steam generators available on the market have a capacity below this threshold, meaning they are not subject to strict regulatory oversight, which reduces installation and operational costs.
Steam generators are widely used in various applications, such as power generation, industrial processes, marine propulsion, and locomotive systems. Power station boilers, for example, are essential for producing electricity by generating steam that drives turbines. Industrial boilers supply steam for heating and production, while marine and locomotive boilers power ships and trains, respectively.
Boilers can be categorized based on their use, pressure levels, and design. Common classifications include low-pressure, medium-pressure, high-pressure, and ultra-high-pressure boilers. In China, power station boilers typically operate at pressures of 3.9 MPa (medium), 10 MPa (high), 14 MPa (ultra-high), and 17 MPa (subcritical). Industrial boilers often function at lower pressures, such as 0.5 MPa, 0.8 MPa, 1.3 MPa, and 2.5 MPa.
Boilers can also be classified based on the flow path of water and flue gas. Fire-tube and water-tube boilers are the most common types. Additionally, circulation modes include natural circulation, forced circulation, direct current, and combined cycle. Combustion methods vary as well, including chamber combustion, layer combustion, and fluidized bed combustion.
The working principle of a steam generator involves several key steps. Raw water is first preheated, then enters the boiler drum, where it flows down through downcomers to the water wall tubes. These tubes absorb radiant heat from the furnace, converting water into a steam-water mixture. The mixture rises through riser tubes back to the drum, where steam is separated from water. The steam is then directed to the superheater, where it is heated further before being sent to the turbine.
In the combustion process, air is preheated and mixed with pulverized coal, which is then injected into the furnace for combustion. The resulting flue gases pass through various heat exchangers, such as the economizer and air preheater, before being expelled through the chimney after dust removal.
Modern boilers incorporate advanced technologies for pollution control, including dust collection, desulfurization, and denitrification. Flue gas purification helps reduce emissions of particulate matter, sulfur oxides, and nitrogen oxides, ensuring compliance with environmental regulations.
Thermal efficiency is a critical factor in boiler performance. Modern power station boilers can achieve efficiencies over 90%, while industrial boilers typically reach 75% or higher. Heat balance tests are conducted to evaluate and improve boiler efficiency, considering both effective heat utilization and losses due to incomplete combustion, excess air, and other factors.
Pure steam generators are specialized devices used to produce high-purity steam, often required in pharmaceutical and food processing industries. They work by evaporating raw water, separating impurities, and condensing the pure steam. This process ensures that the final product meets stringent quality standards.
Overall, steam generators play a vital role in numerous industries, providing reliable and efficient thermal energy solutions. Their design, operation, and maintenance are crucial for ensuring safety, efficiency, and environmental compliance.
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