INDUSTRIAL ONCE-THROUGH STEAM
SOLID FUEL BOILERS

up to 30% more efficient than traditional boilers

INDUSTRIAL ONCE-THROUGH STEAM
SOLID FUEL BOILERS

up to 30% more efficient than traditional boilers

Get a calculation of the economic impact for your enterprise during a free consultation

Get a calculation of the economic impact for your enterprise during a free consultation

ADVANTAGES OF «BENT-IRON» OVER TRADITIONAL STEAM BOILERS

ADVANTAGES OF «BENT-IRON» OVER TRADITIONAL STEAM BOILERS

Practical indicators always differ from theoretical ones. Typically, the description of classic boilers indicates theoretical values of efficiency, fuel consumption, etc., under ideal operating conditions.

However, it’s crucial to understand and consider operational efficiency – this is the actual indicator that reflects the boiler’s effectiveness under real operating conditions, taking into account various operating modes, heat costs for startup, maintaining standby mode, purging, and more.

You can get more detailed information using our savings calculator.

Bent-Iron steam generators feature a heat exchanger in the form of a coil, which has a very low water volume compared to traditional drum boilers. The absence of large pressurized vessels eliminates the possibility of explosion and makes Bent-Iron steam generators absolutely safe.

The once-through steam boiler provides the highest steam quality indicators compared to other types of boilers. The steam dryness is 99.5% at any load and operating mode.

This significantly reduces the content of water and impurities in the steam, ensuring greater energy capacity of the heat transfer medium.

This is particularly important for any food production technologies.

The design of the once-through steam boiler ensures an extremely quick reaction to any fluctuations in steam consumption.

Bent-Iron steam generators rapidly increase and decrease productivity, maintaining stable pressure and high steam quality under any operating conditions.

In steam boilers, blowdowns are necessary to prevent sediment deposition on heat exchanger surfaces. Bent-Iron once-through steam boilers require an extremely low amount of blowdowns and have the capability for highly efficient cleaning of the heat exchange surface. As a result, this saves fuel and chemical reagents used for boiler water treatment.

Bent-iron steam generators have state-of-the-art automation systems based on the Siemens controller. All systems can be controlled via the touch panel on the control cabinet or remotely via the dispatching and remote monitoring function.

The operation of Bent-iron steam boilers does not require the constant presence of an operator.

Thanks to the technological solutions in the design of Bent-Iron steam generators, maintenance costs are minimal. All components have been developed over many years and continue to be improved daily to meet modern technological trends.

Due to their small dimensions, Bent-Iron once-through steam boilers occupy less space compared to traditional drum boilers and require smaller service areas. This significantly reduces the costs associated with boiler room construction and allows for equipment placement closer to the consumer.

Starting a traditional drum boiler typically requires 1 to 2 hours from a cold state. Due to the small number of inert components and the low volume of the heat exchanger, Bent-Iron steam generators reach operating mode in 20-40 minutes. This allows for savings on fuel costs, electricity, and operator labor expenses.

The content of pollutants in the flue gases complies with the requirements of current EU legislation.

MODEL RANGE OF «bent-iron» SOLID FUEL STEAM GENERATORS

MODEL RANGE OF «bent-iron» SOLID FUEL STEAM GENERATORS

STEAM GENERATOR «BENT-IRON»

IDEAL SOLUTION FOR

STEAM GENERATOR «BENT-IRON»

IDEAL SOLUTION FOR

Dairy and cheese production technologies are characterized by highly unstable steam demand, which can fluctuate from 30% to 100% of their capacity in just 5 minutes. This variability requires steam generation systems to have a high level of adaptability and quick response to fluctuations in production needs to ensure uninterrupted technological processes and maintain product quality. Once-through steam boilers are best suited for this task due to their low water content in the heat exchanger and the absence of large inertial components.

Steam is used in brewing processes by numerous breweries worldwide. High-quality steam ensures uniform heating and stable brewing conditions. Market leaders specifically choose once-through boilers because they provide ideal parameters for process steam and save costs through high energy efficiency.

Once-through steam boilers are considered an ideal solution for meat processing plants due to their high efficiency, rapid steam generation, and optimal energy utilization. This type of steam boiler has a low water content, allowing for instant response to the variable steam demand characteristic of the meat processing industry.

Once-through steam boilers provide rapid and efficient steam supply, crucial for precise control of moisturizing and processing in animal feed plants. These boilers have high thermal efficiency, which allows for reduced energy losses and lower operational costs. As a result, animal feed manufacturers can achieve not only high product quality but also increased profitability through cost reduction.

Do produkcji cukierków i wyrobów cukierniczych wymagana jest wysoka precyzja kontroli temperatury w procesach obróbki cieplnej obejmujących pieczenie, karmelizację cukru, przygotowywanie polewy i czekolady itp.

 

To produce the most delicious candies and sweets, confectionery factories require high precision in temperature regulation for thermal processing such as baking, sugar caramelization, glaze and chocolate preparation, etc.
The once-through boiler type is ideally suited for the dynamic production processes of confectionery factories due to its ability to quickly respond to changes in production needs, providing instant increase or decrease in steam supply. This allows for unprecedented accuracy in temperature control.

Steam use in this industry is critical for various technological processes, including oil extraction, refining, and deodorization, as well as for equipment sterilization. Once-through steam boilers provide quick response to changes in production needs and can effectively manage large load fluctuations. This allows enterprises to maintain constant and efficient steam supply, optimize energy consumption, and reduce energy resource costs.

In the wood processing industry, raw materials often have varying moisture levels, so the need for steam for drying, pressing, and wood processing can change significantly. A once-through boiler with rapid operating mode modulation and maintenance of steam quality indicators allows for increased technology productivity and reduces operational costs for steam generation by at least 30% compared to traditional boilers.

Precision temperature control, ensuring stable continuous operation, and ease of maintenance are the main criteria for choosing a steam boiler for an agro-industrial enterprise.

 

The use of once-through steam boilers in agro-industrial enterprises not only contributes to the optimization of production processes and improved product quality but also provides significant economic benefits due to efficient energy use and reduced operational costs.

Traditional steam boilers are often unable to provide an instant response to increased steam consumption or, conversely, a shutdown, leading to significant energy losses and production disruptions, undermining product quality and production efficiency.

 

Once-through steam boilers solve this problem, thanks to their quick start and ability to instantly regulate steam supply according to process needs. Textile enterprises can significantly increase their operational efficiency and energy efficiency.

Once-through steam boilers are a revolutionary solution for the paper and cardboard industry as they provide instant response to changes in production needs. Due to their high thermal efficiency, these boilers significantly reduce energy costs while ensuring stable and precise steam supply for drying processes and other thermal treatments. This not only improves the quality of the final product but also increases the overall productivity of the plant.

Synthesis reaction, distillation, extraction, and purification processes require adherence to precise temperature regimes and uniform heat transfer. This is crucial for the quality of the final product. Once-through steam boilers quickly ramp up and down steam production, allowing for precise maintenance of required temperature conditions while minimizing energy consumption. This allows for reduced energy costs and also contributes to increased production efficiency and product quality. Additionally, the simplicity of maintaining once-through boilers ensures low costs for their operation and upkeep, which is an important factor for enterprises striving to optimize processes.

The pharmaceutical sector encompasses the production of chemical synthesis products such as medicines, oleochemical products (food products, cosmetics), and products related to polymer production (rubber, adhesives, paints, etc.).

 

The production technology includes both continuous and cyclic thermal processing. Cyclic processes, in particular, can involve significant fluctuations in thermal load, from initial high demand to temperature maintenance at the end of the cycle. When using steam, this leads to wide fluctuations in steam requirements.

 

“Bent-Iron” steam generators fully meet these needs. Ease of maintenance and high energy efficiency reduce overall operational costs, minimizing the risks of production downtime and allowing for reduced operational expenses.

STORIES OF OUR CLIENTS

PAYBACK PERIOD LESS THAN 1 YEAR

історії наших клієнтів
окупність мЕНШЕ 1-ГО РОКУ

STORIES OF OUR CLIENTS

PAYBACK PERIOD LESS THAN 1 YEAR

Get a personal calculation of savings and payback in 1 hour.

Get a personal calculation of savings and payback in 1 hour.

MARKET LEADERS HAVE ENTRUSTED US WITH THEIR STEAM SUPPLY

MARKET LEADERS HAVE ENTRUSTED US WITH THEIR STEAM SUPPLY

WHAT OUR CLIENTS SAY ABOUT US

ЩО ГОВОРЯТЬ ПРО НАС НАШІ КЛІЄНТИ

WHAT OUR CLIENTS SAY ABOUT US

«BENT-IRON» BOILER PLANT IS A FULL–CYCLE PRODUCTION FACILITY

«BENT-IRON» BOILER PLANT IS A FULL–CYCLE PRODUCTION FACILITY

Watch the video and get acquainted with our production (duration 2 minutes)

700+ MANUFACTURED COILS
12+ YEARS OF EXPERIENCE

700+ MANUFACTURED COILS
12+ YEARS OF EXPERIENCE

Diameter ranging from 100 mm to 3000 mm and length up to 5000 mm, using one, two, or three tubes simultaneously with specified winding pitches.
Bent-Iron has experience in manufacturing coils for gas steam boilers and heat exchangers of leading global manufacturers — from Germany to the USA, as well as for thermal oil boilers and heat exchangers for process equipment.

Thorough inspection of all materials to ensure their compliance with high standards. Intermediate checks at each stage of manufacturing to ensure all technical parameters are met.

Final hydraulic pressure tests exceeding 100 bar, guaranteeing strength and leak-tightness.

Leave your request, and we will discuss your needs and prepare a customized solution.

THE SECRET TO SAVING AT LEAST 30% on FUEL

Quick Start

Starting a steam boiler requires warm-up time, which depends on the water volume of the heat exchanger and the weight of the concrete lining. The thermal energy needed for heating is a direct loss. Once-through steam boilers have 3-4 times less water volume, and the weight of the concrete lining in Bent-Iron boilers is 5 times less than in traditional boilers. Consequently, heat losses during startup are significantly lower

No Continuous Blowdown

Continuous and periodic blowdowns from the boiler drum and other elements are an integral part of traditional boiler operation.

Bent-Iron boilers only require periodic blowdown from the steam separator. This allows for the removal of “impurities” with a highly concentrated flow, drastically reducing thermal and material losses.

8 Times Lower Losses with Irregular Consumption

In real operating conditions, steam consumption is irregular and unstable.

Traditional boilers experience significant losses during sudden load changes, especially with a sharp decrease in steam consumption. Bent-Iron steam generators, thanks to their small water volume and advanced control system, almost instantly modulate the operation of all systems and significantly reduce heat losses.

4 Times Lower Standby Losses

Most often, the need for steam is cyclical. Maintaining a traditional boiler in standby mode at “idle” consumes a significant amount of energy. A once-through steam boiler, due to its design, consumes far less energy to maintain a hot state.

У чому секрет економії мінімум 30% на паливі

THE SECRET TO SAVING AT LEAST 30% on FUEL

Quick Start

Starting a steam boiler requires warm-up time, which depends on the water volume of the heat exchanger and the weight of the concrete lining. The thermal energy needed for heating is a direct loss. Once-through steam boilers have 3-4 times less water volume, and the weight of the concrete lining in Bent-Iron boilers is 5 times less than in traditional boilers. Consequently, heat losses during startup are significantly lower.

No Continuous Blowdown

Continuous and periodic blowdowns from the boiler drum and other elements are an integral part of traditional boiler operation.

Bent-Iron boilers only require periodic blowdown from the steam separator. This allows for the removal of “impurities” with a highly concentrated flow, drastically reducing thermal and material losses.

8 Times Lower Losses with Irregular Consumption

In real operating conditions, steam consumption is irregular and unstable.

Traditional boilers experience significant losses during sudden load changes, especially with a sharp decrease in steam consumption. Bent-Iron steam generators, thanks to their small water volume and advanced control system, almost instantly modulate the operation of all systems and significantly reduce heat losses.

4 Times Lower Standby Losses

Most often, the need for steam is cyclical. Maintaining a traditional boiler in standby mode at “idle” consumes a significant amount of energy. A once-through steam boiler, due to its design, consumes far less energy to maintain a hot state.

COMPLETE TESTING BEFORE SHIPMENT

COMPLETE TESTING BEFORE SHIPMENT

This operational scheme allows us to verify all systems, eliminate possible manufacturing errors, timely detect all malfunctions, and gain the ability to complete all installation work at the customer’s site in just a few days.

Before making a decision, we provide our clients with the opportunity to see the equipment in operation at facilities or in our test shop.

TECHNICAL SUPPORT AND SERVICE

TECHNICAL SUPPORT AND SERVICE

Professional and high-quality preventive and scheduled maintenance services are crucial for the long-term operation of industrial equipment. We offer a service maintenance contract that includes regular visits by Bent-Iron engineers to perform planned technical maintenance and control of the steam unit to ensure optimal productivity and efficiency.
All Bent-Iron boiler units are accompanied by a comprehensive package of installation and commissioning works performed by qualified Bent-Iron installers and engineers.
Bent-Iron always has spare parts in stock, available for immediate dispatch to the client. To minimize downtime, the client can purchase a set of spare parts and accessories (SPTA) for quick replacement in emergency situations.

Adherence to industrial equipment operation requirements maintains high energy and environmental performance, extends equipment service life, and improves risk management. To ensure quality equipment operation and effective response to various emergency situations, it is crucial to have qualified personnel.

Experienced, qualified, and certified specialists from the Bent-Iron service department conduct training for your personnel both during the initial equipment launch and during each maintenance service.

All training sessions cover general equipment operation principles, detailed explanations of operations, fault diagnostics, scheduled maintenance work, as well as practical operation exercises.

Through remote access, you will have the ability to monitor and control certain steam generator parameters 24/7. Remote access capabilities include:

  • accessibility from various devices (PC, smartphone, tablet)
  • history of all process graphs
  • current status of the unit
  • control of operating parameters such as productivity and pressure
  • information on the amount of process steam produced
  • error history
We are always open to cooperation and partnership. If you have any proposals, please contact us.

CERTIFIED IN UKRAINE AND EU

CERTIFIED IN UKRAINE AND EU