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STEAM BOILERS
Editorial
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Contents
UNIVERSAL U 8
U-ND Low-pressure saturated steam
U-HD High-pressure saturated steam
UNIVERSAL U-MB 10
U-MB High-pressure saturated steam
UNIVERSAL UL-S 12
UL-S High-pressure saturated steam
UL-SX High-pressure superheated steam
UNIVERSAL ZFR 14
ZFR High-pressure saturated steam
ZFR-X High-pressure superheated steam
Philosophy 18
3
UNIVERSAL
Steam boiler
The equipment
pressure gauge stop valve with test flange
pressure gauge
level transducer (4-20 mA)
low-water limiting electronic probe
pressure limiter
manostat pipe
stop valve, maintenance-free
pressure transducer (4-20 mA)
water gauge with
protector and reflector
blow-down stop cock,
water sample tap
burner,
output control
optionally:
2-stage, 3-stage,
modulating
steam valve,
maintenance-free
spring-loaded safety valve
feed water non-return
valve
feed water stop valve,
maintenance-free
water separator
option:
desalting control valve
desalting stop valve,
maintenance-free
water sampling device
conductivity transducer
flame sight hole
automatic blow-down
device 5
blow-down valve,
maintenance-free
Control and safety technology
for all shell boilers
The concept
For decades now, LOOS boiler operating and guarantees solutions that are extremely practical
safety technology has been ensuring convenient and ensures maximum spare part availability.
boiler operation, the highest standards of safety With conventional controls or as SPC-based boiler
and a high level of availability for all steam and management systems with LOOS boiler opera-
hot water generators. The in-house development ting technology, everything's under control.
and manufacture of regulating and safety systems
The result
LOOS BOILER CONTROL LBC
the convenient PLC-based boiler control
A convenient boiler control for LOOS hot water versions. The symbols, graphics and user guidan-
boilers was developed on the basis of an SPC ce are designed in accordance with the latest deve-
automation device which has proved successful in lopments in ergonomics and usability. All available
industry. All the regulating and control functions control and regulating functions can be accessed
are integrated in an efficient, programmable con- intuitively, and actual and setpoint values can be
trol. These include the controls for boiler output, shown in the colour display or changed. The inte-
water level, desalting and blow-down, plus the grated operating signal management system cap-
controls for the Economiser or superheaters. No tures and logs operating states before shut-down
matter whether the boiler is operated with a gas, on faults occurs. Important process data are stored
oil or dual burner, stepped or modulating, with at defined intervals and can be presented on the
mechanical or electric network, LOOS BOILER displays in the form of clear graphs. Analysing data
CONTROL LBC can be used for all systems. is simply child's play. The connection of higher-
level technical management systems via PROFI-
Display and operation are conveniently supported BUS DP or the provision of routers so that the
by TFT colour displays with a touch-sensitive inter- Loos Teleservice can be used are just two of the
face. These are available in 8" or, as an option, 10" many options offered by this system.
level
pressure
conductivity
LBC mounted in
switchgear cabinet
output control
fuel selection
desalting control
level control
automatic blow-down device
6
LBC replaces traditional technology
User benefit
LBC allows the simple optimisation of all mea- LBC can be operated intuitively, since it uses
surement and control functions. Energy con- graphic symbols and presents them on modern
sumption, pollutant emissions and wear and touch-screen displays.
tear are minimised. LBC has integrated protective functions to
LBC ensures maximum supply and operating prevent incorrect operations.
reliability. An extensive operating message LBC is prepared for data exchange with higher-
memory with integrated prewarning systems level technology management systems and
means that incorrectly set regulating para- Teleservice.
meters can be detected and corrected before The Teleservice option allows the user inter-
any safety shut-down occurs. face to be mirrored, so that rapid assistance
LBC ensures maximum operating data trans- can be provided in the event of operating
parency. Many different operating states, ope- problems and to search for faults.
rating data and measured values can be shown
in the graphic touch-screen display.
LBC meets all the special requirements of
modern boiler control and is suitable for later
expansion, modification and modernisation.
The concept
All information is gathered in the comprehensive house components. The plant management system
plant management system LOOS SYSTEM CON- is already prepared for connection to higher-level
TROL LSC. Efficient bus systems guarantee intelli- management systems and the cost-effective LOOS
gent networking of individual boilers and boiler Teleservice.
LSC
LBC LBC
Multiple boiler systems, water analyses, water treatement systems, deaeration systems, condensate systems, fuel supply
LSC has everything under control
7
UNIVERSAL compact boiler
U-ND Low-pressure saturated steam
U-HD High-pressure saturated steam
The concept
Capacity and dimension are particularly designed
for low and medium steam demand as well as for
top-quality manufacture.
The UNIVERSAL steam boiler for 175-1,250 kg/h
(high-pressure steam) and 175-3,200 kg/h (low-
pressure steam) combines the advantages of a
shell boiler with the efficiency of a flame-tube
smoke-tube system.
EC type testing according to the Pressure Vessels
Directive provided for all capacities and pressure
levels (CE). Sectional drawing of boiler type U-HD
The result
Flexible performance for fluctuating steam
demand
Sturdy, reliable and with an unparalleled
service life
Economical and low emission
High pressure stability
High steam quality for demanding users
Stable under peak- and low loads, copes
easily with fluctuating loads
For all burner systems, also NOx-reduced
Stable water circulation and rapid heat transfer
Easy operation and maintenance
Maximum service availability and safety
8
Two U-ND UNIVERSAL low-pressure steam boilers with Two UNIVERSAL high-pressure steam boilers U-HD for
modulating natural gas firing saturated steam generation
The design
Designed and dimensioned according to clearly
defined priorities: furnace size, radiant and con-
vection heating surface, steam space and water
space volume are ideally matched and dimensio-
ned down to the smallest detail. Radiant and con-
vection heating surfaces act in unison to achieve
very rapid water circulation and accelerate the
movement of the steam bubbles to the steam
space.
Smooth heat transfer ensures that the heat genera-
ted by the fuel is converted into steam quickly and
without stress on the material of the boiler. The
flexible ends are rigidly anchored by the full-
length flame tube. All high-pressure boilers are
equipped with additional gusset stays for uniform
load distribution. The front door, hinged right or
left, provides easy access for boiler and burner ins-
pection. High-quality mineral wool mat insulation
covering the entire boiler body and special insula-
ting materials in the front door cut radiation losses
to an insig-nificant minimum. The rigid base frame
reduces the specific ground pressure. All in all a
convincingly good result.
Design
UNIVERSAL Boilers Performance range pressure Temperature Fuel
Series kg/h kW bar g C
9
UNIVERSAL modular boiler
U-MB High-pressure saturated steam
The concept
The product designation U-MB stands for touch screen control, remote serviceability
UNIVERSAL Modular Boiler. The boiler consists and further equipping of the steam boiler are also
of several modules that can be selected in a custo- identical to the large industrial boiler series.
mer-specific way. The relevant elements can be
configured to meet the necessary requirements in This type series has some important innovations
respect of emissions, steam quality and energy in respect of control and regulation. Besides the
efficiency. Thanks to the modular design and con- intuitive touchscreen operation, the steam boiler
sistent use of structural elements and common also includes an automated start-up function, allo-
parts from other type series, it has been possible wing the steam generator to be booted automati-
to achieve an unbeatable price/performance ratio. cally from a cold state at the press of a button or
via an external start signal. It is equipped with an
This 3-pass steam boiler is a universal boiler for all overload protection ensuring premium pressure
applications. Of course, it can be modularly com- stability and steam quality at all times, regardless
bined with all LOOS system components for fuel of consumer behaviour. The customer can then
and water supply, wastewater disposal, water ana- devote his attention to what counts: his produc-
lysis and heat recovery. The programmable tion.
The result
The setup can be exactly aligned with the
customers requirements in respect of emissions,
steam quality and efficiency.
Cost-efficient in spite of proven shell and
3-pass technology
Highest degree of efficiency thanks to the
integrated economiser
Extensive standard equipment
Integrated boiler protection function prevents
overloading of the boiler
Integrated automated start-up for a gentle start
from a cold state
Intuitive touchscreen operation
and SPC control
Less space needed because of the compact
base area
LOOS UNIVERSAL U-MB modular boiler
unique in design and all other features
10
LOOS UNIVERSAL U-MB 3-pass shell boiler
The design
The boiler is designed as a flame and smoke tube in successful use for many years. Of course, as a
boiler in accordance with the Pressure Equipment true 3-pass boiler, there is no need for built-in
Directive. The setup of the basic boiler is based flow components in the smoke tubes.
on the UT boiler design which has already been
Design
UNIVERSAL boiler Performance range pressure Temperature Fuel
Series kg/h kW bar g C
11
UNIVERSAL Single flame tube boiler
UL-S High-pressure saturated steam
UL-SX High-pressure superheated steam
The concept
In the higher performance range, the tried and
tested three-pass principle dominates. The ideal
possibilities for developing high-performance
steam generators with outstanding characteristics
were recognized and rigorously put into practice
by LOOS INTERNATIONAL already in the early
50ies. The UNIVERSAL boiler was designed to
perfection for generating saturated and superhea-
ted steam in the 1,250 - 28,000 kg/h performance Sectional drawing of boiler type UL-S with rear flue gas
range. EC type testing according to the Pressure reversing chamber
Vessels Directive provided for all capacities and
pressure levels (CE). This type series offers with increasing steam out-
The dimensions of flame tube, smoke tube bank, put options for optimising the excellent dynamic
water space and steam space have been thermo- properties and for exploiting futher potential
dynamically optimized for flexible performance. energy savings:
Radiant and convection heating surfaces act in uni- Modulating output control
son to achieve very fast water circulation and Continuous feed water regulation
accelerate the movement of the steam bubbles to Speed-controlled burner fans
the steam space. Smooth heat transfer ensures that O2-control
the heat generated by the fuel is converted into Electronic fuel-/air combination control
steam quickly and without stress on the material of
the boiler.
The result
Flexible output for fluctuating steam demand
Sturdy, reliable and unparalleled service life
Economical operation and low emissions
High pressure stability
High steam quality for demanding users
Stable under peak- and low loads, copes easily
with fluctuating loads
For all burner systems, also NOx-reduced
Stable water circulation and rapid heat transfer
Easy operation and maintenance
Superheated steam from superheater module,
suitable for dry start The three-pass principle of the UNIVERSAL UL-S
Superheater as water separator with
unregulated superheated steam temperature
Superheater with constant controlled super-
heated steam temperature over a wide load
range
Maximum service availability and safety
12
UL-S UNIVERSAL High-pressure steam boiler for saturated UL-SX UNIVERSAL High-pressure steam boiler with
steam generation superheater module for superheated steam generation
The design
The LOOS three-pass patent granted in 1952 Superheated steam is generated by a superheater
forms the basis of the outstanding, still today module. Dimensioned for the required superheat-
unsurpassed success of this series. The flame tube ing temperature and simply placed on the front
(1st pass) and two smoke tube banks (2nd and reversing chamber. By means of a bypass damper
3rd pass) as well as the wet-back rear reversing the superheated steam temperature can be kept
chamber are integrated in the boiler body in an constant over a wide load range. The smoke tube
ideal arrangement. The laterally positioned flame sections remain freely and easily accessible
tube and the horizontal rear- and vertical front through the swivelling reversing chamber door.
heating gas reversal result in the largest possible
radiant and convection heat transfer surface with The high-quality mineral wool mat insulation of
the largest steam space and the smallest external the entire boiler body and of the superheater
measurements. The flexible ends are firmly module ensure that radiation losses are negligible.
anchored by the big, full-length flame tube and The sturdy base frame reduces the specific ground
joined to the boiler casing by a large, LOOS- pressure.
specific number of gusset stays for even load
distribution.
Design
UNIVERSAL Boilers Performance range* pressure Temperature Fuel
Series kg/h kW bar g C
LFO,
UL-S 1,250 to 28,000 1,304 to 18,265 up to 30 up to 235 HFO, Gas
LFO,
UL-SX 2,600 to 28,000 1,820 to 18,265 up to 30 up to 300 HFO, Gas
Data sheets and detailed technical advice are provided for every boiler series
* In some countries national restrictions of the max. permissible output apply
13
UNIVERSAL Double flame tube boiler
ZFR High-pressure saturated steam
ZFR-X High-pressure superheated steam
The concept
The UNIVERSAL double flame tube/smoke tube
boiler is available for output values from 18,000 to
55,000 kg/h with dimensions which allow trans-
port as a ready-to-connect unit. This double flame
tube/smoke tube boiler was developed by LOOS
INTERNATIONAL already in the 50ies and built
with separate furnace gas passages for operation
also with one firing system. The three-pass
principle with rear furnace gas reversing chamber Sectional drawing of boiler type ZFR with rear flue gas rever-
sing chamber and attached flue gas hood
accommodated in the water space was patented
in 1952. The economizer and superheater can be
easily upgraded by the addition of modules. EC For the UNIVERSAL double flame-/smoke tube
type testing according to the Pressure Vessels boiler, modulating output control for unrestricted
Directive provided for all capacities and pressure single- or double flame tube operation and con-
levels (CE). tinuous feed water control are obligatory. This
The dimensions of flame tubes, smoke tube bank, type series offers with increasing steam output
water space and steam space are thermodynami- options for optimising the excellent dynamic cha-
cally optimized. Radiant and convection heating racteristics and for exploiting further energy saving
surfaces, combined with the possibility of single potentials:
flame tube operation, provide special flexibility. speed-controlled burner fan
Rapid water circulation and smooth heat transfer O2-control
ensure that the heat generated by the fuel is electronic fuel-/air ratio control
converted into steam quickly and without stress
on the material of the boiler.
The result
Flexible output for fluctuating steam demand
Sturdy, reliable and unparalleled service life
Economical and low emissions
High pressure stability
High steam quality for demanding users
Stable under peak- and low loads
Individual burner operation/control,
TV-approved for decades
Double control range with efficiency gain
For all burner systems, also NOx-reduced
Stable water circulation and rapid heat transfer Four ZFR UNIVERSAL double flame tube boilers for
Easy operation and maintenance producing saturated steam for parallel or single flame tube
operation
Maximum service availability and safety
Superheated steam from superheater module,
suitable for dry start Superheater with constant controlled super-
Superheater as water separator with heated steam temperature over a wide load
uncontrolled superheated steam temperature range
Design
UNIVERSAL Boilers Performance range* pressure Temperature Fuel
Series kg/h kW bar g C
LFO,
ZFR 18,000 to 55,000 11,160 to 35,800 up to 30 up to 235 HFO, Gas
LFO,
ZFR-X 18,000 to 55,000 12,600 to 35,800 up to 30 up to 300 HFO, Gas
Data sheets and detailed technical advice are provided for every boiler series
* In some countries national restrictions of the max. permissible output apply
15
Flue gas heat recovery
The concept
The flue gas stream from steam boilers contains a sig- To further increase efficiency, stainless steel downstre-
nificant heating potential at a high temperature level. am calorific value heat exchangers can be added. By
The LOOS economiser, with highly efficient top hea- doing so, the flue gas can be brought below the flue
ting surfaces for dry flue gas heat recovery, uses this gas dew point to condensation through cooling.
heating potential to preheat feed water and improve
boiler efficiency.
The result
LOOS steam boiler with integrated economisers
for dry flue gas heat recovery
16
Version A Version B
Feed pump modules Chimney
Leading to the
blow-down
Pump expansion
Econo- modules module
miser
Block diagram of a high-pressure steam boiler system with two flue gas heat exchanger stages (economiser/flue gas condenser)
The effectiveness
106,0
104,0
102,0
98,0
96,0
94,0
Increased efficiency of up to 7 %
in dry operation
92,0
90,0
88,0
20 30 40 50 60 70 80 90 100
Achievable efficiencies with dry flue gas heat recovery and the use of calorific value technology
17
PHILOSOPHY
Company profile
Innovations, quality-consciousness and creativity cou-
pled with more than 140 years of experience form the
basis for LOOS INTERNATIONAL's high-tech boiler
systems. Over 100,000 boiler systems, delivered to
more than 140 countries throughout the world,
demonstrate the outstanding reputation enjoyed by
LOOS INTERNATIONAL's products. Today, LOOS
manufactures 1,500 steam and hot water systems each
year.
18
The result
Two UNIVERSAL UL-S single-flue boilers for saturated Two UNIVERSAL UL-S single-flue boilers for saturated
steam, total system output 32,000 kg/h, pressure 10 bar steam, total system output 8,000 kg/h, pressure 13 bar
One UNIVERSAL ZFR double-flue boiler and one One UNIVERSAL ZFR double-flue boiler for saturated
UNIVERSAL UL-S single-flue boilers for saturated steam, steam, steam output 30,000 kg/h, pressure 22 bar
total system output 50,000 kg/h, pressure 16 bar
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