Smoke Tube Steam Generator

Advantages of Smoke Tube Steam Generator;

• Smoke pipes, ashtray and inferno can be intervened from the front door of the steam generator.
• Our steam generator efficiency for 8-Bar is 90-92% without economiser and 94-96% with economiser.
• They take up little space and produce economical steam in a very short time.
• Due to the low water volume, standby heat losses are very low compared to steam boilers.
• It works automatically and safely. It has successive safety systems.
• It works without much knowledge, maintenance and supervision.
• It has proven itself with hundreds of examples working in global companies for years.
• Custom design according to customer requirements.
• Many years of experience in industrial/commercial boiler technology
• H2 ready
• Precise steam pressure control
• Low maintenance and service costs
• Easy user interface with Tsb Energy control system.
• Reduced operating cost with unattended operation from 24 hours to 720 hours
• High process reliability, remote control is available.
• It undergoes the strictest quality controls throughout the entire production process.
• 2% additional combustion efficiency with aluminium turbulators.
• Low electricity consumption through the use of efficient electric motors.
• Low NOx emissions are available.
• Reduction of CO2 emissions through the combustion of hydrogen by up to 100 per cent.
• Customer-specific software revision specific to your company with our expert staff.
• The boiler can be remotely monitored by integrating it into existing SCADA or similar systems by using PLC that optionally supports Modbus, Modbus TCP, Profinet communication protocols.

It is a factory-operated device, all process tests have been completed, 100% ready for installation. It is delivered compact on a single chassis. All that is required is to connect it to the fuel source, electricity, feedwater and steam users.

The series can produce steam up to 20.000kg/h capacity with cascade connection. Both space saving and fast steam production is ensured.

Working Principle of Smoke Tube Steam Generator;

The working principle of our steam generators with university-supported R&D developments is as follows; The ashtrays of our 2-pass steam generators have been redesigned according to efficient and new generation burners, their diameters have been reduced and their length has been extended and the 1st pass is completed with the combustion cell, 65% of the energy is taken from this part. The flame smoke gases returning from the furnace pass quickly through the 1" pipes surrounding the entire wall and the 2nd pass is completed. The smoke gases that have provided heat transfer pass from the rear smoke box to the chimney without creating a low corrosion effect. In this way, the combustion energy is transferred to the water and the water changes state under pressure.

Design: All boilers are designed and manufactured in accordance with TS EN 12953, Loyd's rules, TRD, DIN, EN, PED 2014/68/EC and ASME Section VIII Div 1 and all electrical components are UL labelled and wired in accordance with the applicable National Electrical Code requirements.

With our university-supported R&D studies, it offers unrivalled efficiency and safety, minimum carbon footprint, easy maintenance and long life. TSB ENERGY steam boilers are designed for you to win while using, not buying.

Ease of Operation and Maintenance: User-friendly controls and easy access to components simplify operation and maintenance, minimising downtime and operating costs. Thanks to a control panel with one-button start-up, self-checking of the device to stop the system against possible faults, and summary maintenance instructions with warnings according to the duration of use, boiler operation has become very reliable and understandable for the boiler operator.

The SG-Special series boilers offer high standards of instrumentation and control, enabling operation without human presence and meeting the constraints of all industrial processes in compliance with CE regulations and the European standard EN12953. Regardless of the intervention mode, between 3 days, 7 days and 720 hours, the boilers operate continuously within authorised limits and automatically stop and interlock when limits are exceeded.

All security devices are monitored by PLC. Necessary safety measures are taken in case of alarm. Boiler control is carried out by the boiler operator via HMI. Active alarms and past alarms are monitored via the same HMI. Alarm and running information is transmitted to other systems via digital contacts (dry contact). Remote data collection and boiler status information are available via ModBus, Modbus TCP/IP and Profinet protocols.

Safety: Safety and standards are our top priority. Our boilers are equipped with advanced safety features such as overpressure protection, in-line water level guards, monitoring of flue temperature, steam temperature and muffle temperatures and emergency boiler shutdown mechanisms.

Material: Envelopes and mirrors of our steam boilers are manufactured from P355GH boiler sheet in accordance with EN 10028-2, nozzle pipes are manufactured from P235GH or P265GH steel drawn boiler pipes in accordance with EN 10216-2.

Efficiency: With the long-term studies of our R&D department, the pipe diameters of our steam boilers and the combustion cell have been narrowed and the length of the boilers has been extended, thus increasing the speed of the smoke gases in the boiler. In this way, less NOx gas is discharged into the environment and high boiler efficiency is achieved by saving at least 2% fuel compared to standard boilers.

100mm thick high density front and rear door insulation provides low heat loss from radiation. The thermal insulation is covered with galvanised and painted DKP sheet with low lambda value. All insulation has low conductivity and high density materials.

In order to increase the efficiency of the steam boiler, aluminium turbulators are optionally placed in the smoke pipes to ensure maximum heat transfer from the smoke gases.

During chlorine production and similar chemical processes, most of the hydrogen gas is released into the atmosphere without being used. This waste and difficult to store hydrogen can be used in our boilers by using suitable burners.

Environmentally Friendly Design:  Our aim is a cleaner environment and for this we try to minimise emissions, In a clean combustion, NOx emissions in our gas-fired boilers: 70 mg/Nm3 in our gas fired boilers and 150 mg/Nm3 in our liquid fuelled boilers.

All of our TSB ENERGY industrial liquid-gas fuelled products can operate with 100% hydrogen by equipping them with a suitable burner that can operate with 100% hydrogen. Since the boiler structure and working principle are designed according to high-speed flame-smoke gases, NOx level remains below the standards even in hydrogen fuel. It also significantly reduces CO2 emissions.

Customisation: We know that every production and process is unique to each business, and we customise our proven equipment based on hundreds of examples and analysis of your process to make it the most suitable and ideal for you. Designing and manufacturing steam boilers and, more importantly, providing the necessary engineering support and personnel for a successful installation requires exceptional expertise. You will not only buy a boiler from us, but also years of experience and know-how. If you have any further questions, please do not hesitate to request an individual expert consultation.

Our customers are offered the following extensions for each boiler:

• Automation and control technology
• Water treatment systems and analysis
• Feedwater tank and other thermal tanks
• Heat recovery systems
• Pipework and chimney systems
• Very high efficiency and low emissions
• Micromodulation as standard
• Simple and easy maintenance
• Robust design for very long life
• Condensing economiser option
• Dual and mixed fuel ignition options
• O2 and CO trim options
• A fully integrated vapour solution.

What is a Smoke Tube Steam Generator?

A steam generator is called a closed pressure vessel in which the combustion energy is transferred from the flame to the water by radiation and conduction, with water as the heat receiving fluid on the outer side of the pipes, and the pipes in which the flame-smoke gases circulate as a result of burning a heat-giving fuel on the inner side of the pipes.

Steam generators are devices that produce instantaneous steam in a short time by instantaneously transmitting the heat energy they have to a small volume of water. They are small and compact due to their small water volume. For these reasons, they cannot respond to sudden steam traction.

When to Use Smoke Tube Steam Generator?

Many plants need steam below 2000kg/h. These enterprises are mostly located in multi-storey buildings. It is not appropriate to put large water volume boilers here in terms of both safety and space occupation. Textile Industry can be given as an example. Here, universal smoke tube steam generators with small water volume, occupying less space, producing steam quickly and not allowing water to be transported with the main steam are placed. Such steam boilers are called steam generators in our country. It is actually a steam boiler.

Very Small Water Volume Boilers
(Steam Generators - Quick Steam Generators)

Water volume and operating pressure play a major role in the explosion risk of boilers. In this respect, if the value in the formula below exceeds 10,000, the boiler cannot be placed inside, under, above or next to the places where people are located or working. It is necessary to put the boiler away from where people are located.

Drawbacks; Due to the large water volume compared to other types of generators, they may cause damage, especially in the event of a furnace collapse or rupture of the outer envelope, as a result of excess vapour emergence.

There are many applications in which our steam boilers cannot compete:

• Where both direct and indirect heating are required at the same time
• Where heat transfer at constant temperature is required, where high heat transfer rates (due to latent heat released during condensation) are required.
• Steam boilers are used to heat large quantities of process hot water due to their stable and efficient heat transfer even at low temperatures.

Areas of Use;

• Hotels, laundries, garments, hosiery industry, knitwear and dry cleaning factories,
• Steam heating systems
• For chemical processes, paint industry, steam washing and cleaning and similar plants,
• In the food industry (production of fruit juice, pasta, cheese and dairy products and large bakeries), beverage bottling industry,
• Feed industry,
• Fertiliser industry
• Vulcanisation of rubber products
• In the pharmaceutical industry for sterilisation purposes
• Building materials industry, concrete curing, aerated concrete production,
• Paper industry
• Refineries
• It is used in areas such as wood processing (wood shaping).