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Introducing the world’s bestHot water and steam boilersIn harmony with your economy and the environment
2Zeta · Heat and steam boilersWe have clients and commissions worldwide.Here is a representative selection.UKRAINEUman GreenhouseCommission: In 2011, Zander& Ingeström installed a 40 MW hotwater boiler at Uman Greenhouse,one of Ukraine’s largest producersof tomatoes and cucumbers. Thanksto cheap night-rate electricity, our customer can run the boiler at full powerand simultaneously chargethe hot water burg, EON-ShamrockCommission: Germany has a longhistory of installing plants thatgenerate renewable electricity usingwind and sun. To take care of thesurplus electricity that naturally occursin these facilities, our boilers areinstalled. They convert the surpluselectricity to heat/steam that can thenbe distributed into the district heatingnetwork or to an industrial business.
ReferencesThe Great Wall of China, one of the world’s new seven wonders, is nearly 9,000 km long. But it cannot be seen from the moon.CHINAAnguang, Jilin,Changchun, RizhaoCommission: In 2013, we deliveredfour different plants to China. Theseboilers utilize low electricity rates atnight and temporary surplus of electricity from wind power. The largestplant in Rizhao consists of four 40 MWboilers, making it the world’s largestelectric boiler plant. The entire deliveryincluded 11 boilers, with a total outputof 250 MW. Furthermore, we deliverauxiliary steam boilers to four Chinesenuclear power plants in Haiyang,Changjiang, Rongchen and Lufeng.SVERIGEHallsta Paper MillCommission: We were asked toreinforce the boiler house at HallstaPaper Mill, where we previouslysupplied a 40 MW boiler. The newboiler has a capacity of 60 MW anda design pressure of 32 bar, making itthe largest in Sweden. Hallsta PaperMill is one of our oldest customers.In 1917, our company’s founder,Bengt Ingeström, supplied Hallstawith a steam accumulator.3
4Zeta · Heat and steam boilersProduce heat/steam at night and use itduring the day. That is a wise policy.Each time power is lost we are invited onan unwanted trip back to the days beforecivilization. The entire modern society is dependent on a stable supply of electricity, andit being produced around the clock. Theproblem is that electricity cannot be stored, and must beconsumed at the same time and the same rate as it is provided. Electricity that is not used is wasted, without doingany good. This happens every night when most electricpower-driven machines and appliances are not in use.The world’s best electric boiler is called Zeta, and is manufactured by the Swedish engineering firm Zander & Ingeström in two basic models: a boiler for steam productionin industries and power plants, and a model for hot waterproduction in plants and hot water networks.The electric-powered Zeta boiler thus replaces all heatand steam boilers fueled by oil, coal and other fossil fuels, whose flue gases contribute to global warming andpollute soil and water. Investing in a Zeta boiler is, in otherwords, also an investment in a cleaner environment.Zeta boiler, a future wise investmentSeveral areas of usageAn elegant solution to the problem of excess electricity isto allow an electric boiler to convert it to steam or heat thatcan be utilized in district heating and industrial processes.This is a solution that is highly interesting for power andprocess industries that advantageously can allow the boiler to work at night when electricity is available at low price.Using excess electricity with the help of Zeta boilers haslong been common in northern Europe, where the availability of electric power has been historically good, withlarge surpluses from hydro and nuclear power. But thereare more uses. An electric boiler is perhaps more expensive to run than a fossil-fired boiler during the day – but
Mission and MarketA geyser is a hot spring where boiling water or steam spurts out of the ground, like nature’s very own fountain.The word geyser comes from the name of a single Icelandic geyser, Geysir.The Zeta boiler’sapplications:1Steam and hot water productionwhen the price of electricity is low2Night accumulation3Conversion of renewablepower to heat and steam4Auxiliary boiler for powerand paper industryFigure 1usually not at night when electricity prices are lower. Consequently, we at Zander & Ingeström have installed a largenumber of accumulator plats in, among other places, China, where the steam/heat is produced and stored overnight and then used during the day.A third application area has arisen due to the rapid expansion of green power in Europe (wind, biogas and solar). These grids need to be regulated for the obvious reason that a wind turbine, for example, produces electricitywhen the wind blows – not when the industry presses theon button. This fact is the reason why more than 25 Zetaboilers are in operation in Denmark alone.A fourth application assists the power industry, wherethe Zeta boiler acts as an auxiliary boiler. It generatessteam when the plants start up, and it provides steamproduction when the plants are shut down.Zander & Ingeström has supplied boilers for powerplants in France, Germany, China, Finland and Sweden.5
6Zeta · Heat and steam boilersThe needs are global,the solution is at our office in SwedenThe market for electric-powered heat andsteam boilers is global. All industrializedcountries have the same energy needs andhave to take into account the conditionsand rules concerning economy and the environment (see Figure 1). That is why the phone rings hereat Zander & Ingeström wherever in the world the needarises, because it is common knowledge that we deliverthe best boiler and the best total solution.Zetas developmentOur leading position in the world is no accident, but a natural consequence of long and dedicated work, based onsolid technical expertise and a visionary product.The engineering company Zander & Ingeström wasfounded in 1898, and built the first electric boilers alreadyin the 1920s. Customers gave the thumbs up but wantedlarger sizes and higher voltage, which started the actualdevelopment of the Zeta boiler, whose international breakthrough came in 1932 with six boilers sold to Finnish Enso.Since then we have delivered thousands of boilers, ranging from a few kW to complete plants up to 150 MW.We are, objectively, the most qualified supplier of electric-powered steam and heat boilers. We have not onlybuilt the largest boilers, but also installed by far the most.Zeta’s characteristicsToday’s Zeta boiler is the fruit of long practical experience,where our products and systems have been refined closeto perfection. The result is a boiler that is characterized byhigh reliability, extremely high efficiency and low noise. Thecapital cost is low and the need for maintenance minimal(see Figure 2).
Mission and Market Our customers are from all overthe world with a particular emphasis onEurope and Asia, where we are representedby local dealers and workshops.Water’s boiling point is determined, as we all know, by the atmospheric air pressure. At sea level water boils at 100 C,but on Mount Everest’s peak is starts boiling at 68 C.The best solutionThe Zeta boiler’s properties:EfficiencyCapital cost Low capital cost incombination with minimalmaintenance.Steam quality The boiler’s steamquality meets the highestdemands.VoltageCapacity controlFigure 2 Extremely high efficiency,as well as accessibility andcontrol accuracy. Feeding voltage canbe selected between6-20 kV for all models. Variable capacity controlfrom 0 to 100 percent.Minimum load is 0 percent.The Zeta boiler is certainly the jewel in the crown, but thefact is that we have a product that is even more important,namely to always offer the best solution for each customer – both economically and environmentally. This meansthat our assignment can include everything from manufacturing, delivery, installation and commissioning, to service, maintenance and training, including peripherals andanything else needed to be able to offer the best solution.Yes please!The Zeta boiler is, in other words, a future wise investmentthat will please the engineer, the financial manager andthe environmental manager – and that probably does nothappen every day.Or to put it in another fashion, ”Calvados, cognac orwhiskey with your coffee?” Answer: ”Yes please!”7
8Zeta · Heat and steam boilersWe offer a full line of boilers,from the smallest to the very largestThe Zeta boiler is equipped with an electrodesystem and intended for connection tothree-phase alternating current. The boiler isguaranteed to never boil dry, because theelectric power is cut off automatically if theelectrodes are not surrounded by water. (The guaranteefollows the laws of physics: It’s the water that makes upthe boiler’s heat-generating resistance.) The supplied energy is converted directly into heat, and the effect in theboiler is controlled by the water level of the electrodes being raised or lowered.FixturesThe Zeta electrode boiler (Figure 3) is comprised of anouter pressure vessel (boiler shell) and an inner cylindricalvessel, mounted on brackets or insulators in the shell.The three-phase electrodes are located in the inner vessel. They are manufactured in a molded material and eachelectrode is comprised of a number of bar electrodes,which are mounted in a single electrode plate. Eachphase electrode is suspended in insulator bushings at thetop of the boiler.The inner vessel, which also forms the electrical system’s zero point, divides the boiler into two water compartments (the inner vessel and the outer vessel). At thebottom of the inner vessel there is a control valve; the actuator is mounted on the outside of the boiler.The circulation pump (supplied as part of the equipment) is connected with the suction pipe to the boiler’souter vessel. The pressure line branches in the boiler into A Live steam line, B Blow down,C Incoming feed water, D Circulation circuit Schematic diagram of the steam plant. A De-aerator,B Feed water tank, C Boiler, D Live steam line
Steam boilersClouds do not actually consist of water vapor – which is an invisible gas – they consist of water droplets or ice crystals or a mixture of both.three pipes, connected to the inner vessel under eachphase electrode. The circulation pump is speed controlledand the flow in the circuit varies with the load.Zeta electrode boilers can be supplied with directlyground zero point, or high- impedance ground zero point.In the latter case, the inner vessel is stripped back fromthe outer vessel with insulators and all piping connectionsbetween the vessel and the outer vessel are made of insulating material. The boiler is thermally insulated with mineral wool covered with aluminum or steel cladding.ily adjusted by changing the water level, and hence theelectrode’s active surface. The circulating pump movesthe boiler water from the outer vessel through the distribution pipes to the inner vessel.CAFunctionBAn electric boiler installation consists mainly of an electrode boiler and circulation pump, fittings, control equipment, instrumentation and control panels with PLC control. As mentioned above, the electric energy is converteddirectly into heat energy by electrical current that is passedthrough the boiler water. Water is an electrical resistanceand is heated by the current.The size of the current passing through the water depends on the electrode’s active surface and the conductivity of the water. The current intensity/power can be eas-ZDKI/ZDK20002500270032003400Capacity (MW)Capacity (t/h)Height 28-4242-638400 60 908900Diameter (mm)Shipping weight (tons)Pressure test weight eral dataVoltage kVInsulation thickness (mm)Material dished ends and shell6-20200P295GHControl rangeRegulating time min/max (min)Design pressure0-100 %550EfficiencyMax. conductivity (feed water ) (uS/cm)Design PED 97/23/EG or ASMEStandard EN 12953 Figure 3. Zeta Electrodesteam boiler. A inner vessel,B outer vessel, C electrode 99 % 59
10Zeta · Heat and steam boilersOur range of boilers coversall needs – at least in our solar systemThere are two models of Zeta boilers for various customer needs. The ZBVA boiler isbased on the same principles as our steamboilers, and consists of an inner and outervessel. The power output is directly proportional to the level of liquid in the inner vessel.Since an electric boiler requires a treated water, a waterloop is also installed between the boiler and the heat exchanger. The boiler constitutes the water loop’s expansionvessel.This type of boiler can be used when the minimum loadmust be low and the control speed high. Load range is0-100 percent, and the boiler can be on stand-by with themain switch on, without taking any power from the highvoltage grid. The boiler comes with high-ohmic isolated ordirectly grounded zero point. Hot water boiler with circulation pump and heat exchanger.ZBVA withinner and outervessels. The poweris directly proportional to the levelof water in theinner vessel.
Heat boilersThe Grand Prismatic Spring in Yellowstone National Park is the largest hot spring in the United States. The water temperature varies between 63 C and 87 C.Boiler model ZVPI/ZHPIWhen requirements for safety, efficiency and accessibilityare particularly high it is a good idea to choose a ZVPI/ZHPI model. These boilers use the same water over andover again in the boiler circuit. The conductivity is constantover time and bottom blows and ventilation is not required.The boilers have one or two electrodes per phase, depending on size. The water passes through the electrodesand is then heated up. The power is controlled by movable screens that cover the electrode to varying degreesdepending on the desired power output. When the electrode is maximally shielded the boiler is in minimum load.The control range is 8-100% of maximum power, andregulating time from minimum to maximum is about threeminutes. Control cabinet for boiler ZVPI 1808,installed just south of Beijing.ZVPI/ZVP16001800200025002800Capacity (MW)Height (mm)Width (mm)Length 016-2453003250470024-406750Diameter pressure vessel including insulation (mm)Pipe connectionShipping weight (tons)Pressure test weight 4183000400830General dataVoltage kVInsulation thickness (mm)Material dished ends and shell6-20100P265GHControl rangeRegulating time min/max (min)Design pressure (bar e)Operating pressure (bar e)8-100 %3162 till 3Design temperature CMaximum operating temperature CEfficiencyStandard EN 12953204180 99 %11
12Zeta · Heat and steam boilersThe art of designing and manufacturing,supplying and installing a boiler systemThe heart of the boiler systems that Zander& Ingeström deliver is our pressure vesselsand control systems. Everything is manufactured in house and all designs are approvedby an accredited independent inspectionServiceOnce the customer has taken over operation of the plant,we are on hand with different types of service programs.Replacement parts are always in stock and can be delivered within 24 hours.authority.The commission routinesEvery new commission is firmly rooted in best practices,where we begin with design reviews and establish schedules and specific quality plans.The actual manufacturing is done with carefully selected suppliers that we in most cases have a longstandingrelationship with. There are several reasons why we donot have your own workshop: We get more capacity because we can have several manufacturing units operatingat the same time. We keep costs down. And we canlocate manufacturing close to you, our customer.TurnkeyWe install complete turnkey plants inSweden. In other countries, we havecontracted partners that tailor installations to suit local conditions.CommissioningThe moment of truth is at theactual start-up when we test allfunctions, such as security, functionality and ioning
From design to commissioningIn 2009, NASA announced that they had found water on the moon. But all the initiated know that Tintin was first.He discovered water on the moon as early as 1953, in ”Destination Moon”.12231Customer requirements andour technical expertise2Power plant standardWell-known brands3Carefully selected representatives around the world4Absolute controlover the operation4413
Zeta · Heat and steam boilersOur suppliers meet the samehigh quality conditions that we doZander & Ingeström boiler systems are qualityconstructions at all levels and in all functions.We manufacture the core products ourselves,but a delivery includes pumps, instruments,control valves and valves – and some ofthese products come from other companies.There is no substantive difference, because we demandthe same high standards of our suppliers that we do ofourselves. Or to put it more concretely: When we assessa supplier, we control product quality, reliability and technical expertise, as well as the code of conduct and service,Kvalitetsexempel14while the price comes last on our specifications. To makethis even more concrete: We only work with well-knownbrands, and all the components in every delivery are ofgood power plant standard. See the examples below.Asia and EuropeFor transportation and environmental reasons, we manufacture bulky and heavy products as close to our customers as possible. So we manufacture pressure vessels inboth Asia and Europe.1Cirkulationspumparav god industristandard2Cirkulationspumpari API-utförande3Värmeväxlare förseddmed packningar, alternativti helsvetsat utförande4Luftdrivna ställdon medpositioner borgar för snabboch noggrann reglering
Our suppliersBreathtaking Iguazu Falls, on the border between Brazil and Argentina, consists of 275 different waterfalls.Close to two million gallons of water passes over Iguazu Falls every second.1324 An operator panel is used to runthe plant locally. It is connected via,for example Profibus, to the mastercontrol system.15
16Zeta · Heat and steam boilersIn addition to our formal certificates we seeeach commission as a new certificationThat Zander & Ingeström is the world’s leadingsupplier of electric heat and steam boilers, aswell as all kinds of industrial pumps, is something that we daily prove in practice. But inaddition, we naturally also fulfill various formalcompetence criteria.our business affects the environment: be it manufacturing,transportation and installation, operation, maintenance,repair or disposal of our products. We are not contentwith just surpassing current environmental laws and regulations – we are continually working to get even better.Since the environment is a shared responsibility, we impose strict requirements on our principals and suppliers.ISO 9001:2008ISO 9001 is an internationally recognized seal of qualitythat the company in question is to be trusted across theboard: in the internal work, the relationship with customers and, of course, in terms of delivered products andservices. It also means that we are constantly working tofurther improve the quality of our company’s managementsystem.Environmental PolicyZander & Ingeström’s environmental program is our commitment to take an active responsibility for how every partTrace Code of ConductZander & Ingeström has also committed itself to the TraceCode of Conduct, which implies an absolute requirementto comply with all laws and regulations (even in lawlesscountries), as well as an absolute prohibition of briberyand improper gifts and services. We are also required toavoid any relationship that is commercially inappropriateor in any way unsound. A membership in Trace obligates:Violation of the rules will lead to immediate expulsion.In short, the Trace Code of Conduct is good old decencywith a new twist.
ISO / Environmental Policy / Code of ConductBoth are beautiful, but sunsets are redder than sunrises, because the atmosphere contains more particles after the day’s activity than after the night’s rest. ISO 9001:2008 means,in short, that the holder isa company you can trust. Naturally,Zander & Ingeströmis a financially stablecompany with highcredit ratings.17
18Zeta · Heat and steam boilers At Zander & Ingeström’s headquarters in Täby, north of Stockholm, we have twenty-fiveemployees. Around the world, our partners and affiliates employ an additional twenty-five.Though globally dispersed, we form a closely-knit group that has worked together for manyyears developing know-how, experience and a great loyalty to our customers – and thus alsoto our own business. No one could wish for a better foundation to build on for the future.
This is Zander & IngeströmFog occurs when the air is so saturated with microscopic water droplets that visibility is less than one kilometer.(No poet has been involved in the writing of this description.) Inspired bythe opportunitiesthat the steamturbine opened up,Bengt Ingeströmand Oskar Zanderfounded theengineering firmZander & Ingeströmback in 1898.Swedish technological and industrial history hasseveral prominent figures that through talent,strong vision and hard work laid the foundations of the modern welfare society that manytoday take for granted. One of these figureswas Bengt Ingeström. He saw a glorious future in steamturbines, and together with his colleague Oskar Zanderhe started the engineering firm Zander & Ingeström. Theyear was 1898.The young company marketed steam turbines and centrifugal pumps. With a nose for market needs and technologies, Zander & Ingeström developed new products whilethe business grew and conquered more areas. And thesame kind of innovative work and dedication has continued through the years.Today, Zander & Ingeström has a leading position in theglobal market – largely thanks to the legacy of Bengt Ingeström. Dedication, work satisfaction and optimism live onin today’s close-knit group of employees.19
www.tulipanaros.seWhile waiting for someone to invent the steam camera, we take joy in the steamboiler, that does a lot of good around the world, when it replaces fossil fuel combustionby converting excess electricity to heat/steam for district heating and industries.Zander & IngeströmBox 7206 · SE-187 13 TäbyStreet address: Tillverkarvägen 11Tel 46 8 80 90 00E-mail zander.ingestrom@zeta.seHome page www.zeta.se
4 Zeta · Heat and steam boilers Produce heat/steam at night and use it during the day. That is a wise policy. The world's best electric boiler is called Zeta, and is man-ufactured by the Swedish engineering firm Zander & Inge- ström in two basic models: a boiler for steam production in industries and power plants, and a model for hot water
