FIRE-TUBE BOILER

Economics and efficiencies[edit]

Excessive cycling[edit]
Each time a boiler cycles off and on, it can lose efficiency. When the fire starts combustion efficiency
is usually lower until steady state conditions prevail. When the fire stops the warm chimney
continues to draw additional air from the interior space until it cools.
Excessive cycling can be minimized

 Modulating boilers can run longer (at firing rates that match the loads) than the non-
modulating boilers (which operate at the full firing rate).
o By using condensing modulating boilers.
o By using non-condensing modulating boiler.
o By setting the controls (thermostats or controller with temperature sensors)
with greater temperature differentials between STOP and START.
 At Non-Condensing Boilers make provisions so that minimum return water temperature
of 130 °F (54 °C) to 150 °F (66 °C) to the boiler to avoid fireside corrosion.
o By setting the MINIMUM OFF times at 8 to 15 minutes. For comfort heating
loads, short time intervals do not usually trigger occupant complaints. [7]
Common provisions are to provide a primary piping loop with pump(s) and a secondary piping loop
with pump(s); and either a variable speed controlled pump to transfer water from the primary loop to
the secondary loop, or a 3-way valve to divert water from the secondary loop to the primary loop. [8]
Fireside corrosion in non-condensing boilers[edit]
A minimum return water temperature of 130 °F (54 °C) to 150 °F (66 °C) to the boiler, depending on
the specific design, is used to avoid condensing water vapor from the flue gas and dissolving CO2
and SO2 from the flue gasses forming carbolic and sulfuric acid, a corrosive fluid that damages the
heat exchanger.[9]

Condensing boilers[edit]
Condensing boilers can be 2% or more efficient at lower firing rates by extracting the heat of
vaporization from the water vapor in the flue gases. The efficiency increase depends on the fuel and
the available energy to be recovered as a fraction of the total. Methane flue gas containing more
available energy to recover than propane or fuel oil relatively less. The condensed water is corrosive
due to dissolved carbon dioxide and sulfur oxides from the flue and must be neutralized before
disposal.[9]
Condensing boilers have a higher seasonal efficiency, typically 84% to 92%, than non-condensing
boilers typically 70% to 75%. The seasonal efficiency is an overall efficiency of the boiler over the
entire heating season as opposed to the combustion efficiency which is the boiler's efficiency when
actively fired, which excludes standing losses. The higher seasonal efficiency is partly because the
lower boiler temperature used to condense the flue gas reduces standing losses during the off cycle.
The lower boiler temperature precludes a condensing steam boiler and requires lower radiator
temperatures in water systems.
The higher efficiency of operating in the condensing region isn't always available. To produce
satisfactory domestic hot water frequently requires boiler water temperature higher than allows
effective condensing on the heat exchanger surface. During cold weather the building's radiator
surface area is usually not large enough to deliver enough heat at low boiler temperatures so the
boiler's control raises the boiler temperature as required to meet heating demand. These two factors
account for most of the variability of the efficiency gains experienced at different installations.