Smoke-tube steam generator
Low-water-content generator on one skid with burner, water treatment and panel, raising steam in 5–10 minutes
TSB Energy
- ≤ 2500 kg/h
- ≤ 16 bar
- ≤ 20 000 kg/h (in cascade)
The smoke-tube steam generator is a compact steam boiler with a small water content that raises steam quickly. It has a two-pass design: the burner flame completes the first pass in the furnace, where according to TSB 65 % of the energy passes to the water, and the returning flue gas then sweeps through 1-inch tubes lining the shell wall to complete the second pass. It delivers up to 2500 kg/h of steam (up to 1750 kW) at up to 16 bar and produces steam within 5–10 minutes; units connected in series or cascade reach up to 20 000 kg/h.
It fires natural gas, LPG, LNG, diesel and heavy fuel oil, and up to 100 % hydrogen with a suitable burner. At 8 bar, efficiency is 90–92 % without an economiser and 94–96 % with one; optional aluminium turbulators in the smoke tubes add 2 % combustion efficiency. Shell and tube plates are P355GH (EN 10028-2) and nozzle pipes P235GH or P265GH (EN 10216-2); design and manufacture are based on EN 12953, PED 2014/68/EU, TRD and ASME VIII Div. 1.
It suits plants that need less than 2000 kg/h of steam and often work in multi-storey buildings, such as textile mills, where a boiler holding a lot of water would be unsuitable for safety and space reasons. Hotels, laundries, dry cleaning, food and beverage, animal feed, pharmaceuticals, chemicals and paints, concrete curing and aerated concrete production are typical users. The SG-Special series, with extended instrumentation, is equipped to operate without staff in line with EN 12953.
Smoke-tube steam generator
- Front door gives access to the smoke tubes, furnace and reversal chamber
- Small footprint; steam within 5–10 minutes
- Low water content keeps standby heat losses far below those of conventional steam boilers
- Automatic, safe operation with successive safety systems, needing little expertise or supervision
- 24 to 720 hours of unattended operation
- At least 2 % less fuel than standard steam generators
- Commissioned once fuel, power, feedwater and the steam line are connected
- Hundreds of units in service at global companies for many years
Smoke-tube steam generator
Skid-mounted equipment
Burner, electrical panel, condensate tank, feedwater pump, water filter and automatic softener are mounted on the same skid as the generator, which leaves the factory already run and process-tested.
Key specifications
| Specification | Smoke Tube Steam Generator |
|---|---|
| Steam output | ≤ 2500 kg/h (single unit) · ≤ 20 000 kg/h (in cascade) |
| Thermal capacity | ≤ 1750 kW |
| Operating pressure | ≤ 16 bar |
| Time to steam | 5–10 min |
| Efficiency | At 8 bar: 90–92 % (without economiser) · 94–96 % (with economiser) |
| Fuel types | Natural gas, LPG, LNG, diesel, heavy fuel oil, H₂ (up to 100 % with a suitable burner) |
| Design | 2-pass: furnace + 1-inch smoke tubes around the shell |
| Unattended operation | 24–720 h |
| NOx emissions | Clean combustion: < 70 mg/Nm³ (gas firing) · < 150 mg/Nm³ (oil firing) |
| Material | Shell and tube plates: P355GH (EN 10028-2) · nozzle pipes: P235GH / P265GH (EN 10216-2) |
Approvals and standards
- EN 12953 — shell boilers (design and manufacture)
- PED 2014/68/EU — Pressure Equipment Directive (design and manufacture)
- TRD — German technical rules for steam boilers
- ASME VIII Div. 1 — pressure vessels (design and manufacture)
Accessories
- Water treatment systems and water analysis
- Feedwater tank and further thermal storage tanks
- Condensing economiser
- O₂ and CO trim control
- Firing options for two fuels or fuel mixtures
- Aluminium turbulators for the smoke tubes (2 % extra combustion efficiency)
- SCADA integration via a PLC supporting Modbus, Modbus TCP and Profinet
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