Effectively managing condensate—the water formed when steam cools and condenses—is essential for keeping a steam system running efficiently and reliably. Two common solutions are condensate return tanks and boiler feed systems. This article explains what each one does, how they differ, when to use them, and offers a basic idea of how they’re sized. For detailed sizing information, check out the tech tip section of our newsletter.
What a Condensate Return Tank Does and When You Need One
A condensate return tank is used when returning condensate can’t flow back to the boiler by gravity alone. This might happen due to elevation differences, long piping runs, layout constraints, or when steam pressure is too high for the condensate to overcome. The tank collects condensate and uses a float switch to activate a pump that sends the water back to the boiler. It’s a straightforward solution that helps maximize system efficiency by recycling hot water and reducing energy consumption.
What a Boiler Feed Pump Does and When You Need One
A boiler feed system ensures the boiler always has the water it needs by responding directly to the water level inside the boiler. It can handle both condensate and make-up water and is ideal for multi-boiler systems, high-pressure applications, setups with uneven or delayed condensate return, or any system where automatic control can reduce maintenance needs and improve reliability.
Unlike a condensate return tank—which pumps based on how much water is in the tank—a boiler feed system activates as soon as the boiler's water level drops. This is critical when condensate returns slowly or inconsistently. Without it, the boiler could run dry and risk damage. A boiler feed system prevents these issues, ensuring stable, consistent operation.
The Bottom Line
If your system layout or pressure conditions make gravity return difficult, a condensate return tank is the practical choice. If you need automatic water level control, especially in more complex or high-pressure systems, go with a boiler feed system.