PROCESS EQUIPMENT UPDATE
BETTERBOILERS I
Advanced electrode boilers dramatically reduce the risk of explosion, fire and noxious emissions associated with fossil-fuel burning units
n industry, gas-fired boilers have largely been the standard for many decades to produce steam as well as heat process water. However, not all
boilers are created equal in terms of safety. By definition, combustion-fuelled boilers can emit harmful vapours, leak gas and even cause explosions and fires. In a recent example, a natural gas boiler was cited as the cause of a massive explosion and fire at a food processing plant in Oregon, USA that injured six and caused severe damage to the facility’s main building. Given the risks, many processors are turning to a new generation of electric boilers to dramatically reduce these hazards. “With gas burning boilers, any gas leak can increase the risk of an explosion wherever there are fuel lines, fumes, flames or storage tanks. So, gas units must be continually monitored or periodically inspected,” says Robert Presser, vice president of Acme Engineering Products, who notes that state and municipal safety guidelines vary depending on boiler type and the expected frequency of inspection. Acme Engineering is a North American manufacturer of boilers for large industrial and commercial applications.
AN EXPLOSIVE TOPIC In gas-fired boilers, explosions can result in the ignition and instantaneous combustion of highly flammable gas, vapour or dust that has accumulated in a boiler. Te force of the explosion is often much greater than the boiler combustion chamber can withstand. Minor explosions, known as flarebacks or
blowbacks, can also suddenly blow flames many feet from firing doors and observation ports, seriously burning anyone in the path of a flame. Natural gas-fired boiler emissions also pose potential hazards in the form of emissions.
As safer electrode boilers become more widely available, companies can protect their people and processes more while minimising required maintenance
Tis can include nitrogen oxides (NOx), carbon monoxide (CO), nitrous oxide (N2
sulphur dioxide (SO2 (CH4
matter (PM), as well as the greenhouse gasses carbon dioxide (CO2
O), volatile organic compounds (VOCs), ), and particulate
) and methane
), which accelerate global warming. In addition, fossil fuel burning boilers can also face potentially dangerous operational issues stemming from excessive heat accumulation, particularly if the water is too low in the system to properly absorb the heat. High heat conditions can compromise the boiler, electrodes and other equipment essential to operation. To dramatically improve operator
and environmental safety, the industry is
turning toward modern electric boilers that eliminate many of these risks. Te most advanced electrode boilers not only match the capacity of large gas or oil-fired boilers but are also safer and more compact, maximising energy efficiency, improving reliability and minimising maintenance.
Although many facility engineers are familiar with gas-fired boilers, many believe that electric boilers cannot match the output of the traditional, fossil fuel burning units. Due to considerable advances in electric boiler technology, however, such technology can now match the capacity of large gas or oil-fired boilers in a much smaller footprint.
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