Gas fired boiler is a high-efficiency energy conversion equipment that uses natural gas, liquefied gas, city gas and other gases as the main fuel. Exploring the operating mechanism of gas fired boilers is the key to further understanding the basic principles and performance of this heating equipment. EPCB Boiler will conduct an in-depth analysis to understand how the gas boiler operates to reveal its efficient energy conversion process and the operating principle of providing reliable heating to users.

1.Working Principle of Gas Fired Boiler

The basic working principle of a gas fired boiler is based on burning gas in the furnace to release high-temperature heat energy. By heating the water in the boiler, the water is heated and evaporated, and finally stable and controllable steam is produced. This thermal energy conversion process mainly involves two key aspects: combustion process and thermal energy conversion.

First, fuel, usually natural gas or LPG, is piped into the combustion chamber. In the combustion chamber, the ignition system triggers the ignition process, causing the combustion of gas. This combustion process is a chemical reaction in which fuel partially burns with oxygen in the air, producing heat, water vapor and carbon dioxide.

The entire combustion process is carried out quickly and accurately in the gas fired boiler to ensure efficient energy conversion, maximize the use of fuel energy, and provide a stable heat source for the heating system. The control and optimization of this process is a key consideration in the design of modern gas boilers, aiming to increase thermal efficiency, reduce emissions, and ensure equipment reliability.

Next, enter the heat energy conversion stage, which is the process of burning fuel to generate high-temperature flames, and then transferring this heat energy to the water in the boiler, and finally heating the water into steam or providing hot water. This is the core function of the gas fired boiler. Through this A process in which water is heated and converted into hot water or steam, depending on the design and purpose of the boiler.

The hot water or steam generated is then transported to areas that require heating, such as heating systems or industrial processes, to meet the corresponding energy needs. The entire process achieves efficient conversion from the chemical energy of fuel to practical thermal energy, making gas fired boilers widely used in fields such as heating, production and power generation.

2.Main Components of Gas Boiler System

2.1 Structure of Gas Fired Boiler System

The fired boiler is mainly composed of burner, boiler body, control system, water circulation system, gas supply system and smoke exhaust system.

As a complex energy conversion system, a gas boiler includes multiple key components, each of which plays a unique role and together ensures the efficient operation of the entire system.

2.1.1. Burner

The burner is a device that introduces gas and ignites it. It is responsible for mixing gas with an appropriate amount of air to form a flammable mixed gas and triggering a combustion reaction through the ignition system.

2.1.2. Boiler body

The gas fired boiler body consists of a combustion chamber and a boiler shell with double-threaded smoke pipes arranged inside. The combustion chamber is the area where the combustion process occurs. The mixed gas encounters an ignition source in the combustion chamber, triggering a partial combustion reaction and producing high-temperature hot gas.

2.1.3. Control system

The control system monitors and regulates the operation of the entire boiler system. It includes sensors such as temperature, pressure and ignition, as well as controls that can adjust the supply of gas and air as needed.

2.1.4. Smoke exhaust system

The smoke exhaust system is used to exhaust the smoke generated during the combustion process. It ensures that exhaust gases are discharged smoothly, and some systems also include devices to recover waste heat to improve energy efficiency.

2.1.5.Gas supply system

Gas valves control the flow of gas, ensuring that gas supply matches system demand.

2.2 Gas Boiler Overall workflow:

The burner introduces gas and mixes it with air.

The burner ignites the gas mixture through the ignition system.

The combustion process takes place in the combustion chamber, producing hot gases at high temperatures.

The heat exchanger transfers heat energy to the water, causing the water temperature to rise.

The hot water or steam generated is piped to the area that needs to be heated.

3.Gas Boiler Startup Process

The start-up process of a gas boiler is a carefully designed sequence to ensure that the system starts operating under safe and efficient conditions. Here are the general steps for starting up a gas boiler, from ignition to hot water or steam production:

3.1. Preparation

System Check: Before starting, perform a system check to ensure that all components and equipment are in proper working order. Check gas supply, electrical connections, water flow, etc.

Exhaust system inspection: Make sure the exhaust system is smooth and the smoke exhaust passage is unobstructed to ensure the smooth discharge of exhaust gas.

3.2. Gas supply preparation

Open the gas valve: Open the gas valve gradually to ensure that the gas supply is gradually established and the required flow rate is achieved.

Ignition preparation: Check the ignition system to ensure that equipment such as ignition electrodes and flame sensors are in good condition.

3.3. Ignition process

Introducing air: Before igniting a fire, make sure the right amount of air is mixed with the gas to create a flammable mixture.

Ignition: The ignition system is activated, the ignition electrode generates sparks, ignites the mixed gas, and starts the combustion process.

Combustion chamber heating: As ignition proceeds, the temperature in the combustion chamber gradually increases, and the combustion process gradually stabilizes.

3.4. Flue gas circulation generates heat exchange

The fuel is injected into the furnace from the burner at the front of the boiler, and burns in the furnace to produce high-temperature flue gas that enters the backfire chamber. The flue gas enters the front smoke box from the backburner through the second return threaded smoke pipe. The flue gas enters the rear smoke box from the front smoke box through the third return smoke pipe, then passes through the economizer, and is finally discharged into the atmosphere through the chimney.During the circulation of flue gas, the water temperature gradually rises to form hot water or steam.

3.5. System adjustment

Control system adjustment: The control system begins to monitor parameters such as temperature and pressure, and adjusts the supply of gas and air to maintain stable operation of the system.

Through the above steps, the gas boiler can safely and quickly go from ignition to hot water or steam generation during the startup process, meeting the needs of heating, production and power generation.

4.Heat Energy Transfer Process

The thermal energy transfer process of a gas boiler is the process of converting the thermal energy of the fuel into the thermal energy of water, and finally providing steam or hot water. This process involves key steps such as combustion, heat energy transfer and water circulation.

4.1Combustion process: 

Gas boilers first mix fuel (usually natural gas, liquefied gas, etc.) with air through a burner. In the combustion chamber, the mixed gas is ignited to form a high-temperature flame. This combustion process causes the chemical energy within the fuel to be released as heat energy.

4.2 Radiation and convection heat energy transfer: 

The high-temperature flame transfers heat energy to the boiler body through radiation and convection. Radiation is transmitted through the smoke tube and directly acts on the surface of the gall body to heat it up. Convection is the movement of gas around the flame, which transfers heat energy to the water in the tank.

4.3 Heating and circulation of water:

The boiler tank is filled with water. Thermal energy transfer causes the water temperature to rise, thereby increasing the water's thermal energy. The heated water begins to undergo convection, that is, hot water rises and cold water falls, forming a natural circulation of water. In a steam boiler, the heating of water eventually causes the water to vaporize, forming steam.

4.4 Utilization of steam or hot water:

The generated steam or heated hot water can be used in different applications such as heating, industrial production or hot water supply. In a steam boiler, the steam is usually piped to where it is needed, while in a hot water boiler, the hot water can be used directly for heating or other purposes.

5.Frequently Asked Questions and Maintenance of Gas Boilers

Anticipating common problems and maintaining your gas boiler is crucial to ensuring the efficient operation of your equipment. The following are some common problems that may occur and corresponding maintenance methods:

5.1 Water Pressure Issues: 

Water pressure that is too high or too low in your gas boiler can cause problems. If the water pressure is too high, drain some water to reduce the water pressure. If the water pressure is too low, gradually increase the water pressure through the boiler water inlet valve or the exhaust valve in the system to ensure that the water pressure is within the normal range. Regularly checking and adjusting water pressure are important maintenance steps.

5.2 Exhaust problem:

The boiler exhaust system may be blocked. The cause of the blockage may be dust accumulation in the flue or moisture condensation, which affects the combustion efficiency. The flue should be cleaned regularly to ensure that dust and carbon deposits do not affect the exhaust. Regular inspection and cleaning of exhaust channels is necessary.

5.3 Water quality issues:

Poor water quality can lead to scale and corrosion inside the boiler. Regularly use water softening equipment to treat the water entering the boiler to reduce the mineral content in the water. Using a water softener or regularly cleaning the inside of your boiler is part of maintenance.

5.4 Auto-ignition issues:

 If the auto-ignition system fails, the boiler will not start properly. Inspecting and maintaining the ignition system, including the electrodes and spark plugs, are important steps.

5.5 Leakage problem:

Check the boiler and its connections for leaks. Repair possible leaks promptly to prevent water damage and reduced boiler performance.

5.6 Regular cleaning:

Dust and debris will accumulate inside the boiler, affecting heat exchange efficiency. Regular cleaning of the inside of your boiler, including the heat exchanger and combustion chamber, is key to ensuring efficient operation.

5.7 Regular inspection and service:

It is best to have regular inspection and service performed by professional technicians. They can identify potential problems and perform necessary maintenance and repairs.

Through regular maintenance and timely repair, you can ensure long-term efficient and safe operation of your gas boiler, reducing energy waste and unnecessary repair costs.

6.Conclusion

Gas boilers play a vital role in industrial systems, providing necessary heat energy to production processes, thereby increasing the efficiency and reliability of industrial operations. Their efficient heat transfer and adaptability make them the first choice in industries as diverse as manufacturing, chemical engineering and food processing. By providing reliable heating solutions, gas boilers help reduce energy costs and increase productivity, becoming an indispensable asset in industrial environments.