A 500 HP steam boiler delivers roughly 7.8t/hr of steam, serving mid-size industrial and commercial processes. Expect base equipment to cost $75 000–$150 000, depending on design, material thickness, and basic control features.
| Category | Price Range | Notes |
|---|---|---|
| Base Equipment | $75 000 – $150 000 | Firetube at the low end; basic watertube at the high end |
| Low-NOₓ Burner Kit | +10 % of base price | Burner assembly, controls and oxygen trim for emissions compliance |
| Economizer | $5 000 – $10 000 | Recovers waste heat from flue gas to preheat feedwater |
| Feedwater Package | $7 000 – $12 000 | Pump skid, deaerator tank, instrumentation |
| Installation & Piping | +10 % – 20 % of base | Foundations, flue stack, auxiliary piping, electrical hookups |
| Pre-Owned Units | $75 000 – $100 000 | Refurbished shells with varying controls and remaining warranty |
1. Base Equipment
Firetube vs. Watertube: Firetube boilers are simpler and start around $75 000, suitable for lower pressures and steady loads. Watertube designs—better for higher pressures (up to 600 psi) and fluctuating demands—approach $150 000. Materials (carbon steel vs. alloy) and shell thickness influence price within this band.
2. Emissions Control
Meeting modern NOₓ limits typically requires a dedicated burner kit. Plan for +10 % of the boiler price to cover low-NOₓ burners, oxygen-trim controls, and safety interlocks. Though it raises upfront cost, this kit often pays back via fuel optimization and avoids regulatory penalties.
3. Heat Recovery (Economizer)
An economizer captures residual flue-gas heat to preheat feedwater, costing $5 000–$10 000. Benefits include a 3–5 % fuel-use reduction and cooler stack temperatures, which extend refractory life. In high-fuel-cost regions, simple payback can be under two years.
4. Feedwater Treatment
Proper water treatment prevents corrosion and scale. A typical $7 000–$12 000 package includes a deaerator tank, feed pump skid, and monitoring instrumentation (conductivity probes, blowdown control). Skimping here risks tube failures and unplanned shutdowns.
5. Installation & Piping
Installation—foundations, flue stack, steam headers, condensate lines, electrical wiring—adds 10–20 % to the equipment price. Early collaboration with mechanical and civil contractors secures firm quotes and minimizes costly change orders during construction.
6. Pre-Owned Options
Used 500 HP boilers trade at $75 000–$100 000, offering 20–30 % savings on base price. However, budget separately for hydrostatic testing, control upgrades, and possible tube replacement. Limited or no factory warranty means factoring in potential service and parts costs.
7. High Efficiency Steam Boiler (500HP)
Different models of 8 ton/h steam boilers produce steam at 194°C under 1.25 MPa pressure, using feed water at 20°C.
| Model | Steam Pressure (Mpa) | Natural Gas Consumption (Nm³/h) | Product size L×W×H(mm) |
|---|---|---|---|
| WNS-8 | <3.8Mpa | 550.69 | 7122×3413×4114 |
| θ6-8000 | <2.5 | 553.7 | 6805×2570×3680 |
| θ7-8000 | <3.8Mpa | 544.07 | 6520×3860×4295 |
Conclusion
By combining the concise cost table with targeted insights on each component, you can:
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Compare “apples-to-apples” quotes by insisting on line-item pricing
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Balance initial capex with long-term fuel and maintenance savings
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Avoid surprises through early site engineering and detailed scopes
With this guide, you’re equipped to budget confidently for a 500 HP steam boiler project between $75 000 and $150 000.
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