Q: What are the essential differences between a steam generator and a traditional boiler?
A: The core differences lie in pressure control and structural design. Traditional boilers are pressure vessels that must withstand high pressure (usually ≥0.1MPa) and require registration for the use of special equipment. In contrast, most steam generators operate at low pressure (some products have a pressure <0.1MPa), feature a more compact structure, and do not require cumbersome approval procedures for special equipment. They also have faster start-up and shutdown speeds, making them more suitable for scenarios with small to medium steam demand (such as food processing and small-scale heating).
Q: What types of fuels are used for steam generators, and how to choose among different types?
A: Common fuels include electricity, natural gas, liquefied petroleum gas (LPG), biomass pellets, and diesel. The choice should be based on the application scenario: ① For indoor scenarios with high environmental requirements (such as food factories and laboratories), electric heating or natural gas-fired models are preferred, as they produce no exhaust emissions. ② In rural areas or regions rich in biomass resources, biomass pellet-fired models are a cost-effective option. ③ For temporary sites without gas or electricity supply (such as outdoor construction), diesel-fired models can be used for emergency purposes, but attention must be paid to exhaust gas treatment.
Q: What are the water quality requirements for using a steam generator? What are the impacts of substandard water quality?
A: Softened water that meets the standards of Industrial Boiler Water Quality (GB/T 1576) must be used; tap water or well water cannot be used directly. If water quality is substandard, calcium and magnesium ions in the water will form scale on heating tubes or heat exchange surfaces, leading to: ① Reduced thermal efficiency (the thermal conductivity of scale is only 1/50 that of metal), increasing energy consumption. ② Local overheating of heating tubes, causing tube burst or damage. ③ Detached scale may block pipelines, affecting the stability of steam output.
Q: Which steps cannot be omitted in the daily operation of a steam generator?
A: Key steps include: ① Pre-startup inspection: Confirm that the water level is within the normal range (not lower than the minimum water level line), pressure gauges/safety valves are in normal condition, and there is no leakage from pipeline valves. ② Preheating after startup: Raise the temperature slowly to avoid damage to heating tubes due to excessive temperature differences. ③ Monitoring during operation: Check water level, pressure, and temperature data every 30 minutes to ensure they are within the rated range. ④ Maintenance after shutdown: Drain residual water (especially in winter to prevent freezing and cracking) and clean the furnace and filtering devices.
Q: If a steam generator suddenly stops producing steam or the steam volume decreases, what might be the causes?
A: Common causes fall into 4 categories: ① Water supply issues: Low water level in the tank, blocked water inlet pipes, or pump failure, resulting in insufficient water to generate steam. ② Heating issues: Burnt-out electric heating tubes, blocked gas nozzles, or insufficient biomass feeding, leading to insufficient heating power. ③ Pressure issues: Malfunctioning safety valves that prevent pressure maintenance, or inaccurate pressure gauges causing misjudgment of pressure. ④ Pipeline issues: Scaling in steam pipelines or valves not fully opened, hindering steam transportation.
Q: Do steam generators require regular maintenance? What are the maintenance cycles and contents?
A: Regular maintenance is mandatory, with different cycles for different components: ① Daily maintenance: Check water level, pressure, and valve status; clean the water inlet filter. ② Weekly maintenance: Clean ash deposits in the furnace (for gas/biomass-fired models), inspect heating tube wiring (for electric heating models), and test the opening performance of safety valves. ③ Monthly maintenance: Inspect the tightness of pipeline connections, clean the water level sensor, and calibrate pressure gauges. ④ Annual maintenance: Replace aged sealing rings, overhaul water pumps or fans, and arrange for safety testing by professional institutions.
Q: What safety precautions should be followed when using a steam generator?
A: Three safety rules must be strictly observed: ① Burn prevention: The surface temperature of steam outlets and pipelines is extremely high; do not touch them with hands, and wear high-temperature-resistant gloves during operation. ② Water shortage prevention: Water shortage can cause dry burning and damage to heating tubes, or even explosions. The equipment must be equipped with a water shortage protection device and must not operate without protection. ③ Overpressure prevention: Do not adjust the safety valve to be loose without authorization or block the pressure release channel. If the pressure exceeds the rated value and the safety valve fails to open, shut down the equipment immediately and troubleshoot the problem.
Q: For different industries (such as food, chemical, and medical), are there any special requirements for using steam generators?
A: Industry-specific differences mainly lie in steam quality and equipment materials: ① Food industry: "Clean steam" must be used to prevent oil stains or impurities in steam from contaminating food. Equipment materials must comply with food-grade stainless steel standards (e.g., 304), and regular disinfection is required. ② Chemical industry: If corrosive media are transported, steam pipelines must be made of corrosion-resistant materials (e.g., 316L stainless steel), and the equipment must have explosion-proof functions. ③ Medical industry: "Medical sterile steam" standards must be met. Steam generators need to be equipped with multi-stage filtration and sterilization devices, and regular microbial testing is required.
Q: How to calculate the energy consumption of a steam generator? How to reduce energy consumption?
A: Energy consumption calculation depends on the fuel type. Taking electric heating models as an example: Energy consumption (kWh) = Heating power (kW) × Operating time (h) × Thermal efficiency (usually 85%-95%). Energy consumption can be reduced in three ways: ① Choose high-efficiency equipment: Prioritize products with thermal efficiency ≥90% and avoid using old, low-efficiency models. ② Optimize operation: Adjust output power according to steam demand to avoid no-load operation, and ensure good thermal insulation of pipelines (to reduce heat loss). ③ Improve water quality: Use softened water to reduce scale, maintain equipment thermal efficiency, and lower heating energy consumption.
Q: When purchasing a steam generator, how to select the appropriate specifications based on one’s own needs?
A: Focus on three key parameters: ① Steam output: Select based on the hourly steam demand (unit: kg/h). For example, if food processing requires 50kg/h of steam, choose a model with a rated evaporation capacity of 50kg/h. ② Steam pressure: Select based on equipment requirements (e.g., a reactor requires 0.4MPa steam), ensuring the generator’s rated pressure is slightly higher than the actual demand (with a 10%-20% margin). ③ Fuel compatibility: Choose the fuel type based on on-site energy supply (e.g., presence of natural gas pipelines, electrical capacity) to avoid unusability due to mismatched energy sources.
