30 ton Gas Steam Boiler Solution for Dairy processing

Steam is used for pasteurization, sterilization, cleaning-in-place (CIP), evaporation and drying, and must be delivered reliably at precise pressure and temperature to ensure product quality and food-safety compliance. At a 30 t/h scale, selecting the right gas-fired boiler configuration directly impacts energy consumption, footprint, redundancy and controllability.

Key Technical Requirements

• Steam Quality & Pressure: Dairy processes typically require saturated steam at 0.7–1.25 MPa (7–12.5 bar) with a dryness fraction ≥ 0.99 to avoid water hammer and ensure consistent heat transfer.

• Efficiency & Emissions: Target overall thermal efficiency ≥ 92 % via multi-pass gas-burner design, economizer and optimized draft controls, while complying with local NOₓ emissions limits.

• Control & Responsiveness: Fast load-following capability (turndown ratio ≥ 5:1) for processes with fluctuating steam demand, plus automated blowdown and blowoff recovery to minimize energy loss.

Scheme 1 ─ Single 30 t/h Horizontal Three-Pass Wet-Back Boiler

Suitable for large dairy processing plants with increased production lines

• Design Highlights:

  • Three-pass wet-back furnace maximizes heat transfer; typical thermal efficiency up to 95–96 %.

  • Integral economizer pre-heats feedwater using flue-gas heat, plus an oxygen-trim control system to optimize combustion.

  • Blowdown heat-recovery unit captures flash steam to preheat makeup water.

  • Turndown ratio 5:1 for stable operation under part-load.

• Advantages:

  • High single-unit capacity simplifies piping and controls.

  • Compact floor layout compared to parallel smaller units.

  • Easier maintenance (one pressure vessel).

• Considerations:

  • Single‐point failure risk without standby unit, unless duplicated.

  • Higher capital cost per kW vs. smaller modules.

Scheme 2 ─ Dual 15 t/h Packaged Boilers in Parallel

This solution is often used in new large-scale dairy processing plants

• Design Highlights:

  • Two identical 15 t/h gas-fired package boilers, each with three-pass fire-tube design.

  • Common header with automated valve sequencing to match load.

  • Shared economizer and blowdown recovery per unit.

• Advantages:

  • Redundancy: one boiler can cover ~50 % of peak demand during maintenance.

  • Load matching: one or both units fire up/down based on steam requirement, improving part-load efficiency.

  • Lower individual vessel weight simplifies transport and installation.

• Considerations:

  • Slightly larger footprint than a single 30 t/h unit.

  • Separate controls and blowdown systems for each module.

• Performance: Expected combined thermal efficiency ~94 %, with full-load COP benefits of parallel modulation.

Scheme 3 ─ Modular SZS Steam Boiler System

This solution is typically used in dairy processing plants with large fluctuations in steam load

• Design Highlights:

  • Multiple modules (e.g., 3 × 10 t/h units) arranged on a single structural skid with a master controller to fire only the number of modules required by load.

  • Integrated skid package houses: boilers, feed-water pumps, softener, control panel, steam header and safety valves within one transportable module.

  • Turndown per module 10:1; overall system turndown up to 30:1.

• Advantages:

  • Maximum flexibility: fine-grain load matching greatly reduces fuel consumption during low-demand periods.

  • Scalability: additional modules can be added as production grows.

  • Rapid installation: factory-tested skid reduces on-site piping and welding.

  • Maintenance stagger: modules can be serviced one at a time without full shutdown.

• Considerations:

  • Higher aggregate footprint for boiler room compared to a single large unit.

  • Slightly higher initial cost per kW, offset by lifecycle savings in fuel and maintenance.

Recommendation & Next Steps

For a 30 t/h steam load with variable demand profiles, Scheme 3 (modular boiler system) offers the best combination of part-load efficiency, redundancy and future expandability. If floor space and capital cost are more constrained, Scheme 1 or Scheme 2 remain robust choices—balancing simplicity against redundancy.

Prior to final selection, conduct a site-specific energy audit to quantify load variability, and verify local emissions requirements. The chosen configuration should then be laid out in a detailed P&I diagram, followed by a control-system design to ensure seamless integration with your dairy-plant automation network.

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