Innovations and technological optimization are key factors in the field of steam boilers, but at the same time the importance of engineering design (sizing) of the plant (or upgrading), based on the production needs of the company and the appropriate use of equipment (staff training), should be stressed.
Steam is one of the most widely used, efficient and flexible means in the food industry for various applications as cooking (as it can reach high temperatures in a short time), sanitization of lines and containers used for food and beverage packaging and for the humidification of environments where a controlled atmosphere is required. Steam quality, its constant availability and its energy efficiency are important to ensure product quality and food safety.
TECHNOLOGICAL EVOLUTION OF STEAM BOILERS
Low NOx emission generators
Steam generators with low oxides of nitrogen (NOx) are a major innovation. These systems are designed to effectively reduce air pollution, helping to comply with increasingly stringent environmental regulations: Some regions impose emission limits below 50 mg/Nm3. This is particularly relevant today for industries that want to promote a sustainable image as required by the European market and green policies. In the evaluation of the plant, the main points to focus on are:
- Complete insulation of the boiler body: it involves not only the boiler body, but also the fumes circuit and hydraulic connections. This is important given the high temperatures and pressures to prevent heat loss and it goes along with a correct evaluation of the most appropriate burner for the boiler and its sizing and adjustment.
- Energy recovery:The plant should be implemented, to increase efficiency, with economizers for example, for heat recovery from exhaust fumes and condensates, as well as automation and control solutions, based on seasonal energy performance assessments and devices to optimize the burner, such as modular fans and residual oxygen regulators.
Another possibility is the condenser: It is an exchanger, which recovers heat at low temperature from the condensation of fumes.
- Assessment of pressure and power values: The plant should be configured according to the real needs of the company, considering all variables concerning energy, logistics and production, to avoid installing inadequate boilers in terms of performance and consumption.
- Water treatment:The feed water of generators should be treated with specific solutions to limit scale and corrosion, thus avoiding damages to the plant and unavoidable maintenance costs.
Modulating boilers
Modulating boilers are another significant technological innovation. These boilers can modulate their steam production in order to provide the exact level of heat needed by the system, minimizing energy wastes and improving efficiency. The ability to adapt and automate also allows to optimize operational costs and reduce downtime.
Integration with automation and control systems
Integration with automation systems is another factor to consider. Modern steam generators are often equipped with advanced control systems that allow real-time monitoring of operating parameters such as pressure, temperature, and consumption. This allows for more precise management and preventive maintenance, reducing the risk of crashes or sudden failures or damages, optimizing operational continuity.
Internet of things (IoT): Modern generators are often equipped with IoT sensors that constantly monitor parameters such as temperature, pressure and water quality. This data is sent to centralized systems that can analyze it in real time, allowing for more precise operation of the generator.
Artificial Intelligence (AI): AI is used to analyze data collected from sensors to optimize generator operations. Advanced algorithms can predict steam demand peaks and regulate boiler operation to minimize energy consumption during periods of low demand. In addition, the AI can identify anomalies in operational data, suggesting timely maintenance interventions, thus reducing downtime.
MATERIAL INNOVATION AND DESIGN
Advanced materials
New metal alloys and protective coatings, such as titanium alloys and ceramic coatings, are designed to better resist corrosion, a common problem in food production environments, where water used to generate steam can contain impurities and frequent lubrication is required. These materials preserve plant life and reduce maintenance costs.
Design
The design of steam boilers has become increasingly compact and customized, enabling easier installation even in confined spaces – this is particularly useful in small and medium food companies where space is often a constraint. While designing a plant, greater attention shall be paid to minimizing blind spots and rough surfaces inside boilers and steam circuits to limit the build-up of food residues, facilitating cleaning and sanitization.
Advanced safety systems
Modern steam generators are equipped with advanced safety systems including automated pressure relief valves, emergency shut-off systems and constant monitoring of operating conditions. These systems not only improve operator safety, but also reduce the risk of accidents that could compromise food production.
ENERGY EFFICIENCY AND SUSTAINABILITY
Assessment of energy waste and heat recovery
A growing trend is the adoption of systems for recovering the heat produced by steam generators, used to produce electricity or to power other parts of the production process. This approach improves the overall energy efficiency of the plant while reducing CO2 emissions.
In the overall assessment of energy losses, one of the critical points are steam venting systems which, if properly managed, reduce the overall emissions of the boiler, for instance by recovering and recycling the steam for process water heating by means of heat exchangers and condensers. This steam reduces water losses and cuts costs accordingly. A further possibility is to place the generators close to the steam supply point: Short pipes have less leakage, the installation is simpler, economical, and faster.
Use of renewable energy and electricity
Integration with renewable energy sources, such as biogas or solar and wind energy, is another innovative development. Some modern boilers can be powered, at least partially, from these sources, further reducing the environmental impact of the food industry and clearly reducing dependence on fossil fuels and related long-term costs.
Natural gas remains the choice for boilers and steam generators; however, the power supply seems to have several advantages: There is no release of CO2 or other gases (zero carbon footprint), it achieves significant levels of conversion efficiency, requires minimal maintenance, and has a simpler structure.
CONCLUSIONS
In addition to possible technological innovations and optimizations, it is a priority to reiterate the importance of the engineering design (sizing) of the plant (or upgrading), based on the production needs of the company and the appropriate use of equipment (staff training): An obsolete or superficially designed boiler can lead to losses in efficiency and exorbitant costs for unforeseen maintenance, related to heat exchangers, condensation exhausts and associated scaling caused by inadequate chemical water treatment.
