Steam has been an essential force in industrial energy production for centuries. From driving the industrial revolution to powering modern industries today, steam continues to play a pivotal role in Australian industries. But how does something as simple as water vapour remain so fundamental in the world of energy production? Let’s dive into the science and history behind industrial steam boilers and explore why they are indispensable to Australian businesses.

The Historical Significance of Steam

In 200B.C, a Greek named Hero developed a novelty machine called an aelopile or rotary steam engine. From this point on the concept of steam being used to do useful work developed until in the early 1600’s when Brance, an Italian engineer developed the first workable steam turbine. The development of the shell boiler, which was basically a kettle heated by a fire, began in earnest in the early 1700’s and was mainly the result of a requirement to drive pumps for the expulsion of water from coal mines using the expansive power of the steam. However, as the requirement for higher pressure steam boilers increased, engineers recognised that the shell boiler had limitations and the development of the water tube boiler began. Williams Blakey’s basic water tube steam generator (1766) was the predecessor of the early water tube boiler and development continued rapidly culminating in the highly complex modern water tube boiler that is capable of operating at high pressure and temperature.

The Affect of Pressure on Temperature of Water and Steam

When water is heated under constant pressure, its temperature increases until a point is reached at which it begins to boil and at this point the temperature of the boiling water remains constant. At any given pressure there is a definitive boiling temperature which is known as the Saturation Temperature. A simple example of this phenomenon would be seen in an attempt to cook an egg at high altitude. Because the water would boil at a much lower temperature than at sea level the egg would take a long time to cook.

What Is Steam?

In industrial applications, steam quality is critical for efficiency and productivity. One important type is dry saturated steam, which is steam that contains minimal water at its saturation temperature. Typically, the steam used in process industries is 99.5% to 99.95% dry saturated steam, making it an excellent medium for transferring energy and driving various processes.

Saturation temperature at sea level (I bar absolute) = 100^oC

Saturation temperature at 9,000m above sea level (approx 0.31 bar absolute) = 69^oC

The Use of Steam

Steam is used as a way of transporting energy to a process. The useful components in the steam are pressure and heat energy. The pressure component “Drives” the steam to the process and the heat component is used at the process.

At the process the steam condenses while giving away the latent heat of vaporisation. This happens due to the temperature difference (called the driving force) between the process medium, (or the product), and the steam. Where this heat transfer occurs by means of a heat exchanger there is no contact between the steam and the product or the process being heated. In these situations the condensate is returned for re-use in the boiler via the condensate return lines.

The advantage of returning condensate to the boiler is twofold:

• The condensate from a closed system is pure water and therefore may not require any further treatment although it may entrain rust from the piping or sometimes the product may leak in to the condensate system.
• The condensate is hot, i.e. still contains the sensible heat of the water, and therefore will require minimal preheating before returning to the boiler, resulting in saving in steam production.

In a direct injection process, steam is introduced directly into the product and therefore no condensate is recovered.

Where steam is used as a heating medium it is important that it contains a minimum of free water droplets. This is because any free water present in the steam contains no latent heat of vaporisation and is therefore inefficient as a heat source

Why Steam Remains Indispensable

Today, steam continues to be used as an energy source due to its efficiency in transferring energy. Steam’s pressure moves it through systems, while the heat component powers different processes. As steam releases its heat, it condenses and returns latent energy that can be recycled, making it a cost-effective energy solution.

In industries across Australia, this recycling of energy and water reduces the need for additional water treatment and preheating, saving both time and money. In applications where steam is injected directly into products, it is crucial that the steam is free of water droplets to ensure maximum efficiency.

Industries Relying on Steam Boilers

Several industries in Australia depend on industrial steam boilers to maintain efficient production. For instance, in the food preparation business, steam is a critical component for sterilising equipment, cooking, and even in the production of various food products. Similarly, breweries rely heavily on steam to heat water for brewing processes, sterilise equipment, and control temperatures during fermentation. Without an efficient steam system, these businesses would face significant operational challenges.

The gas turbine industry also benefits greatly from the steam produced by industrial boilers. Steam is used in power generation, helping to drive turbines and produce electricity efficiently. Whether it’s a boiler sale, boiler installation, or gas burner industrial solutions, steam is integral to the energy sector.

As industries continue to evolve, the demand for efficient energy remains a priority. Our boilers not only offer a way to recycle energy but also help our customers to maintain temperature, drive productivity, and support the innovation of diverse sectors across Australia.

At Tomlinson Energy, we understand the vital role that our industrial steam boilers play in our customer’s operations. Whether you’re looking for new boiler installation, need regular boiler maintenance, or require emergency boiler repair, we’re here to help. Our team has decades of experience in providing top-quality industrial boiler solutions, including boiler sale and gas burner industrial services.

If you want to ensure that your operations remain efficient and reliable, don’t hesitate to contact us. We’re here to support the future of your business.

When you need boiler maintenance, installation, or repair, call us at your state-specific telephone number. Alternatively, you can fill out our online contact form and we will get back to you.

Maximising Boiler Performance and Longevity Through Regular Service by ensuring your boiler remains in top condition is crucial for its performance and longevity. Getting regular boiler service isn’t just about addressing minor issues before they become major problems. Regular boiler maintenance is a proactive approach to maintaining efficiency, safety, and cost-effectiveness. In this blog, we’ll explore why routine boiler maintenance is essential, how it helps prevent costly repairs, and the benefits it brings in terms of energy savings and safety.

Avoiding Costly Repairs Through Regular Service

Regular boiler service is a key strategy for avoiding expensive repairs and ensuring your system runs efficiently. During routine maintenance, Tomlinson Service technicians can identify minor issues that, if left unattended, could lead to major breakdowns. For instance, a simple adjustment or part replacement during a service can prevent a boiler from developing a serious fault that might otherwise result in costly repairs. Regular check-ups not only extend the life of your boiler but also optimise its performance, preventing inefficiencies that could increase operating costs.

Extending the Lifespan of Your Boiler

When engaging in regular servicing, you ensures that all components are in optimal condition, preventing wear and tear that can lead to premature failure. During routine check-ups, our technicians inspect and clean critical parts, which helps to avoid the accumulation of debris and sediment that can strain the system. By addressing minor issues before they escalate, scheduled maintenance prevents major malfunctions and extends the overall lifespan of your boiler. Investing in regular maintenance enhances the reliability of your system and ensures it operates efficiently for many years to come.

Improving Safety and Compliance

Our routine services identifies potential safety hazards such as gas leaks, faulty components, and carbon monoxide risks before they become serious problems. Our technicians perform thorough checks to ensure your boiler meets all safety standards and operates efficiently, reducing the risk of accidents and ensuring a safe environment for everyone. Additionally, adhering to regular inspection schedules helps you stay compliant with local regulations and avoid penalties, giving you peace of mind that your boiler is both safe and legally compliant.

Reducing Energy Consumption

Ongoing and regular boiler service plays a key role in reducing energy consumption and lowering utility bills. By ensuring that your boiler operates at peak efficiency, routine maintenance prevents inefficiencies such as heat loss and unneeded energy expenditure. During a service, technicians clean and calibrate components, adjust settings, and replace worn parts, all of which contribute to optimal performance. A well-maintained boiler uses less energy to heat your space, translating into lower fuel costs and more economical operation. Regular servicing not only helps you save on energy bills but also enhances the overall efficiency and reliability of your heating system.

Does Your Boiler Need Immediate Attention?

Identifying early signs that your boiler needs immediate service can prevent small issues from escalating into costly repairs. Watch for these warning signals:

· Unusual Noises: If your boiler starts making clanking, banging, or high-pitched whining sounds, it could indicate internal problems such as air in the system or a failing component.

· Inconsistent Heat: Inconsistent heating or fluctuations in temperature can signal issues with the boiler’s efficiency or functionality.

· Leaking or Dripping: Any signs of leaks or drips around the boiler should be addressed promptly, as they may point to internal pressure problems or failing seals.

· Warning Lights or Error Codes: Modern boilers often have diagnostic systems that display error codes or warning lights when there’s a problem. Check the boiler’s manual for specific meanings and act quickly.

· Increased Energy Bills: A sudden spike in your energy bills can be a sign that your boiler is working harder than it should, possibly due to inefficiency or malfunction.

If you notice any of these signs, it’s crucial to schedule a service with us as soon as possible to avoid further damage and ensure your boiler is running safely and efficiently.

Looking to Maximise your Boiler Performance?

Maximise your Boiler Performance and Longevity Through Regular Service with Tomlinson Energy Service. We are experts in boiler maintenance and repair, as well as steam boiler installation. Proudly backed by 100 years of engineering and service experience, we can provide you with exceptional customer service and unparalleled steam boiler expertise. Proud business unit of The Environmental Group, providing a 24/7 national service, maintenance and repair team.

When you need boiler maintenance, installation, or repair, call us at your state-specific telephone number. Alternatively, you can fill out our online contact form and we will get back to you.