Three Pass Steam Boiler

Advantages of Three Pass Steam Boiler;

• Reduced operating cost with unattended operation from 24 hours to 720 hours.
• It responds to sudden vapour draws.
• It has a large evaporation surface and vapour volume.
• It has a large and corrugated combustion surface.
• It can be intervened to the smoke pipes from the front doors of the steam boiler, to the inferno side through the large diameter explosion door behind it, to the water side through the man hole on the boiler and at least two hand holes.
• Our steam boiler efficiency for 8-Bar is 90-92% without economiser and 94-96% with economiser.
• Waterback or Dryback design
• 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.
• High process reliability, remote control is available.
• The strictest quality controls throughout the entire production process.
• 1.5% 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 optionally equipped with a PLC with different communication protocols such as Modbus, Profibus, etc. and thus boiler integration into any industrial process can be provided.

3 Pass Scotch Type Steam Boiler Working Principle;

The working principle of our steam boilers with university-supported R&D developments is as follows; The ashtrays of our 3-pass steam boilers have been redesigned according to the efficient and new generation burner, their diameters have been reduced and their length has been extended. With this combustion cell, the 1st pass is completed, 55% of the energy is taken from this part. Short smoke pipes have been lengthened even more due to the lengthening ashtray and narrowing inferno, and the smoke gases entering the inferno pass through these pipes and the 2nd pass is completed. Smoke gases coming to the front smoke box through the pipes placed in the water body by making it narrower, with the lengthening boiler length, the 3rd passage is completed by passing through the long smoke pipes that are even longer. 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.

The boiler is delivered compactly on a single chassis ready for operation. All that is required is to connect it to electricity, feed water and steam users.

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.

SB- 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 chamber 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 far below the standards even in hydrogen fuel. At the same time, CO2 emissions are significantly reduced.

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
• Combustion air preheater
• Dual and mixed fuel ignition options
• O2 and CO trim options
• A fully integrated vapour solution.

What is a Three Pass Steam Boiler? When to Use Three Pass Steam Boiler?

Steam boilers are closed pressure vessels in which the combustion energy is transferred from the flame to the water by radiation and conduction, with water as a heat receiving fluid on the outer side of the pipes, and on the inner side of the pipes, there are paths consisting of short and long pipes in which flame-smoke gases circulate as a result of burning a heat-giving fuel.

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.

Ideal Steam Boiler Selection;

• First of all, efficiency should be considered, the highest efficiency of a steam boiler is 80% load condition. Therefore, 1/5 of the capacity of the steam boiler to be selected is the primary selection criterion.
• If the steam required by the enterprise varies too much during the day, for example, if there are 1.5-2 times differences, the steam boiler should definitely be considered redundant, and the backup steam boiler should be activated and the regime should be provided when the steam demand increases with check valve counterbalancing through a single common collector.
• The steam pressure value and steam capacity required by the enterprise should be calculated correctly by avoiding rounding from a technical point of view, many enterprises round up when determining their needs and by purchasing a larger steam boiler and steam installation than they need, on the contrary, it leads to a decrease in the speed of steam and inefficient steam energy consumption. The steam boiler should be selected with clear and accurate data.
• Steam should be delivered to the devices using low pressure steam at high pressure and here it should be drawn to the desired pressure range with the help of a pressure reducer, in this way, steam will be delivered to the device with a smaller diameter pipe and a drier steam will be obtained.
  If there is no need for steam in the plant, steam boiler should not be used for heating purposes, hot water boiler or superheated water boiler systems should be used according to the thermal capacity of the plant due to high initial installation and operating costs.
• When selecting the steam generator, the instantaneous steam extraction amount should be taken into consideration, if these values are too high, a steam accumulator should be added to the system or a water pipe steam generator that is activated in a short time should be installed.
• While arranging the boiler room, working conditions and boiler classification rules required by local administrations should be taken into consideration.

Areas of Use;

• Steam turbines
• Steam heating systems
• Chemical processes
• In the food industry (production of juice, pasta, cheese and dairy products, as well as large bakeries),
• also used in sterilisation.
• Fertiliser industry
• Vulcanisation of rubber products
• In the pharmaceutical industry for sterilisation purposes
• Building materials industry
• Paper industry
• Refineries
• It is used in areas such as wood processing (wood shaping).