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A steam engine is a heat engine that performs mechanical work using steam as its working fluid. The steam engine uses the force produced by steam pressure to push a piston back and forth inside a cylinder. This pushing force can be transformed by a connecting rod and crank into force for work. The term "steam engine" is most commonly applied to reciprocating engines as just described, although some authorities have also referred to the steam turbine and devices such as Hero's aeolipile as "steam engines". The essential feature of steam engines is that they are external combustion engines, where the working fluid is separated from the combustion products. The ideal thermodynamic cycle used to analyze this process is called the Rankine cycle. In general usage, the term steam engine can refer to either complete steam plants (including boilers etc.), such as railway and , or may refer to the piston or turbine machinery alone, as in the beam engine and stationary steam engine.
As noted, steam-driven devices such as the aeolipile were known in the first century AD, and there were a few other uses recorded in the 16th century. In 1606 Jerónimo de Ayanz y Beaumont patented his invention of the first steam-powered water pump for draining mines. Thomas Savery is considered the inventor of the first commercially used steam powered device, a steam pump that used steam pressure operating directly on the water. The first commercially successful engine that could transmit continuous power to a machine was developed in 1712 by Thomas Newcomen. James Watt made a critical improvement in 1764, by removing spent steam to a separate vessel for condensation, greatly improving the amount of work obtained per unit of fuel consumed. By the 19th century, stationary steam engines powered the factories of the Industrial Revolution. Steam engines replaced Sailing ship on , and steam locomotives operated on the railways.
Reciprocating piston type steam engines were the dominant source of power until the early 20th century. The efficiency of stationary steam engine increased dramatically until about 1922. The highest Rankine Cycle Efficiency of 91% and combined thermal efficiency of 31% was demonstrated and published in 1921 and 1928. Advances in the design of and internal combustion engines resulted in the gradual replacement of steam engines in commercial usage. Steam turbines replaced reciprocating engines in power generation, due to lower cost, higher operating speed, and higher efficiency. Note that small scale steam turbines are much less efficient than large ones.
, large reciprocating piston steam engines are still being manufactured in Germany.
A rudimentary steam turbine device was described by Taqi al-DinAhmad Y Hassan (1976). Taqi al-Din and Arabic Mechanical Engineering, pp. 34–35. Institute for the History of Arabic Science, University of Aleppo. in Ottoman Egypt in 1551 and by Giovanni Branca in Italy in 1629. The Spanish inventor Jerónimo de Ayanz y Beaumont received patents in 1606 for 50 steam-powered inventions, including a water pump for draining inundated mines. By 1615, Salomon de Caus developed a solar-powered atmospheric engine. Frenchman Denis Papin did some useful work on the steam digester in 1679, and first used a piston to raise weights in 1690.
In 1720, Jacob Leupold described a two-cylinder high-pressure steam engine. The invention was published in his major work "Theatri Machinarum Hydraulicarum". The engine used two heavy pistons to provide motion to a water pump. Each piston was raised by the steam pressure and returned to its original position by gravity. The two pistons shared a common four-way rotary valve connected directly to a steam boiler.
The next major step occurred when James Watt developed (1763–1775) an improved version of Newcomen's engine, with a separate condenser. Boulton and Watt's early engines used half as much coal as John Smeaton's improved version of Newcomen's. Duty comparison was based on a carefully conducted trial in 1778. Newcomen's and Watt's early engines were "atmospheric". They were powered by air pressure pushing a piston into the partial vacuum generated by condensation steam, instead of the pressure of expanding steam. The engine cylinders had to be large because the only usable force acting on them was atmospheric pressure.
Watt developed his engine further, modifying it to provide a rotary motion suitable for driving machinery. This enabled factories to be sited away from rivers, and accelerated the pace of the Industrial Revolution. (2025). 9780226726342, University of Chicago Press. ISBN 9780226726342
Watt's patent prevented others from making high pressure and compound engines. Shortly after Watt's patent expired in 1800, Richard Trevithick and, separately, Oliver Evans in 1801 introduced engines using high-pressure steam; Trevithick obtained his high-pressure engine patent in 1802, and Evans had made several working models before then.The American Car since 1775, Pub. L. Scott. Baily, 1971, p. 18 These were much more powerful for a given cylinder size than previous engines and could be made small enough for transport applications. Thereafter, technological developments and improvements in manufacturing techniques (partly brought about by the adoption of the steam engine as a power source) resulted in the design of more efficient engines that could be smaller, faster, or more powerful, depending on the intended application.
The Cornish engine was developed by Trevithick and others in the 1810s. It was a compound cycle engine that used high-pressure steam expansively, then condensed the low-pressure steam, making it relatively efficient. The Cornish engine had irregular motion and torque through the cycle, limiting it mainly to pumping. Cornish engines were used in mines and for water supply until the late 19th century.
The acme of the horizontal engine was the Corliss steam engine, patented in 1849, which was a four-valve counter flow engine with separate steam admission and exhaust valves and automatic variable steam cutoff. When Corliss was given the Rumford Medal, the committee said that "no one invention since Watt's time has so enhanced the efficiency of the steam engine". In addition to using 30% less steam, it provided more uniform speed due to variable steam cut off, making it well suited to manufacturing, especially cotton spinning.
In the 20th century, the rapid development of internal combustion engine technology led to the demise of the steam engine as a source of propulsion of vehicles on a commercial basis, with relatively few remaining in use beyond the Second World War. Many of these vehicles were acquired by enthusiasts for preservation, and numerous examples are still in existence. In the 1960s, the air pollution problems in California gave rise to a brief period of interest in developing and studying steam-powered vehicles as a possible means of reducing the pollution. Apart from interest by steam enthusiasts, the occasional replica vehicle, and experimental technology, no steam vehicles are in production at present.
Trevithick continued his own experiments using a trio of locomotives, concluding with the Catch Me Who Can in 1808. Only four years later, the successful twin-cylinder locomotive The Salamanca by Matthew Murray was used by the edge railed rack and pinion Middleton Railway. In 1825 George Stephenson built the Locomotion for the Stockton and Darlington Railway. This was the first public steam railway in the world and then in 1829, he built The Rocket which was entered in and won the Rainhill Trials. The Liverpool and Manchester Railway opened in 1830 making exclusive use of steam power for both passenger and freight trains.
Steam locomotives continued to be manufactured until the late twentieth century in places such as China and the former East Germany (where the DR Class 52.80 was produced).Michael Reimer, Dirk Endisch: Baureihe 52.80 – Die rekonstruierte Kriegslokomotive, GeraMond,
The world's smallest working "steam engine" was revealed in 2011. The micro-scale engine was developed by two German scientists at the University of Stuttgart. It operates on the principle of a Stirling engine.
The widely used reciprocating engine typically consisted of a cast-iron cylinder, piston, connecting rod and beam or a crank and flywheel, and miscellaneous linkages. Steam was alternately supplied and exhausted by one or more valves. Speed control was either automatic, using a governor, or by a manual valve. The cylinder casting contained steam supply and exhaust ports.
Engines equipped with a condenser are a separate type than those that exhaust to the atmosphere.
Other components are often present; pumps (such as an injector) to supply water to the boiler during operation, condensers to recirculate the water and recover the latent heat of vaporisation, and to raise the temperature of the steam above its saturated vapour point, and various mechanisms to increase the draft for fireboxes. When coal is used, a chain or screw stoking mechanism and its drive engine or motor may be included to move the fuel from a supply bin (bunker) to the firebox.
The two most common types are:
Fire-tube boilers were the main type used for early high-pressure steam (typical steam locomotive practice), but they were to a large extent displaced by more economical water tube boilers in the late 19th century for marine propulsion and large stationary applications.
Many boilers raise the temperature of the steam after it has left that part of the boiler where it is in contact with the water. Known as superheating it turns 'wet steam' into 'superheated steam'. It avoids the steam condensing in the engine cylinders, and gives a significantly higher efficiency.
These "motor units" are often called 'steam engines' in their own right. Engines using compressed air or other gases differ from steam engines only in details that depend on the nature of the gas although compressed air has been used in steam engines without change.
The simplest cold sink is to vent the steam to the environment. This is often used on to avoid the weight and bulk of condensers. Some of the released steam is vented up the chimney so as to increase the draw on the fire, which greatly increases engine power, but reduces efficiency.
Sometimes the waste heat from the engine is useful itself, and in those cases, very high overall efficiency can be obtained.
Steam engines in stationary power plants use surface condensers as a cold sink. The condensers are cooled by water flow from oceans, rivers, lakes, and often by which evaporate water to provide cooling energy removal. The resulting condensed hot water ( condensate), is then pumped back up to pressure and sent back to the boiler. A dry-type cooling tower is similar to an automobile radiator and is used in locations where water is costly. Waste heat can also be ejected by evaporative (wet) cooling towers, which use a secondary external water circuit that evaporates some of flow to the air.
River boats initially used a jet condenser in which cold water from the river is injected into the exhaust steam from the engine. Cooling water and condensate mix. While this was also applied for sea-going vessels, generally after only a few days of operation the boiler would become coated with deposited salt, reducing performance and increasing the risk of a boiler explosion. Starting about 1834, the use of surface condensers on ships eliminated fouling of the boilers, and improved engine efficiency.Nick Robins, The Coming of the Comet: The Rise and Fall of the Paddle Steamer, Seaforth Publishing, 2012, , Chapter 4
Evaporated water cannot be used for subsequent purposes (other than rain somewhere), whereas river water can be re-used. In all cases, the steam plant boiler feed water, which must be kept pure, is kept separate from the cooling water or air.
Many engines, stationary and mobile, are also fitted with a governor to regulate the speed of the engine without the need for human interference.
The most useful instrument for analyzing the performance of steam engines is the steam engine indicator. Early versions were in use by 1851, but the most successful indicator was developed for the high speed engine inventor and manufacturer Charles Porter by Charles Richard and exhibited at London Exhibition in 1862. The steam engine indicator traces on paper the pressure in the cylinder throughout the cycle, which can be used to spot various problems and calculate developed horsepower. It was routinely used by engineers, mechanics and insurance inspectors. The engine indicator can also be used on internal combustion engines. See image of indicator diagram below (in Types of motor units section).
The dominant efficiency loss in reciprocating steam engines is cylinder condensation and re-evaporation. The steam cylinder and adjacent metal parts/ports operate at a temperature about halfway between the steam admission saturation temperature and the saturation temperature corresponding to the exhaust pressure. As high-pressure steam is admitted into the working cylinder, much of the high-temperature steam is condensed as water droplets onto the metal surfaces, significantly reducing the steam available for expansive work. When the expanding steam reaches low pressure (especially during the exhaust stroke), the previously deposited water droplets that had just been formed within the cylinder/ports now boil away (re-evaporation) and this steam does no further work in the cylinder.
There are practical limits on the expansion ratio of a steam engine cylinder, as increasing cylinder surface area tends to exacerbate the cylinder condensation and re-evaporation issues. This negates the theoretical advantages associated with a high ratio of expansion in an individual cylinder.
Double-expansion (usually known as compound) engines expanded the steam in two stages. The pairs may be duplicated or the work of the large low-pressure cylinder can be split with one high-pressure cylinder exhausting into two low pressure cylinders, giving a three-cylinder layout where cylinder and piston diameter are about the same, making the reciprocating masses easier to balance.
Two-cylinder compounds can be arranged as:
With two-cylinder compounds used in railway work, the pistons are connected to the cranks as with a two-cylinder simple at 90° out of phase with each other ( quartered). When the double-expansion group is duplicated, producing a four-cylinder compound, the individual pistons within the group are usually balanced at 180°, the groups being set at 90° to each other. In one case (the first type of Vauclain compound), the pistons worked in the same phase driving a common crosshead and crank, again set at 90° as for a two-cylinder engine. With the three-cylinder compound arrangement, the LP cranks were either set at 90° with the HP one at 135° to the other two, or in some cases, all three cranks were set at 120°.
The adoption of compounding was common for industrial units, for road engines and almost universal for marine engines after 1880; it was not universally popular in railway locomotives where it was often perceived as complicated. This is partly due to the harsh railway operating environment and limited space afforded by the loading gauge (particularly in Britain, where compounding was never common and not employed after 1930). However, although never in the majority, it was popular in many other countries.
The image in this section shows an animation of a triple-expansion engine. The steam travels through the engine from left to right. The valve chest for each of the cylinders is to the left of the corresponding cylinder.
Land-based steam engines could exhaust their steam to atmosphere, as feed water was usually readily available. Prior to and during World War I, the expansion engine dominated marine applications, where high vessel speed was not essential. It was, however, superseded by the British invention steam turbine where speed was required, for instance in warships, such as the dreadnought battleships, and . of 1905 was the first major warship to replace the proven technology of the reciprocating engine with the then-novel steam turbine.Brooks, John. Dreadnought Gunnery at the Battle of Jutland. p. 14.
The simplest valve gears give events of fixed length during the engine cycle and often make the engine rotate in only one direction. Many however have a reversing Machine which additionally can provide means for saving steam as speed and momentum are gained by gradually "shortening the cutoff" or rather, shortening the admission event; this in turn proportionately lengthens the expansion period. However, as one and the same valve usually controls both steam flows, a short cutoff at admission adversely affects the exhaust and compression periods which should ideally always be kept fairly constant; if the exhaust event is too brief, the totality of the exhaust steam cannot evacuate the cylinder, choking it and giving excessive compression ( "kick back").
In the 1840s and 1850s, there were attempts to overcome this problem by means of various patent valve gears with a separate, variable cutoff expansion valve riding on the back of the main slide valve; the latter usually had fixed or limited cutoff. The combined setup gave a fair approximation of the ideal events, at the expense of increased friction and wear, and the mechanism tended to be complicated. The usual compromise solution has been to provide lap by lengthening rubbing surfaces of the valve in such a way as to overlap the port on the admission side, with the effect that the exhaust side remains open for a longer period after cut-off on the admission side has occurred. This expedient has since been generally considered satisfactory for most purposes and makes possible the use of the simpler Stephenson, Joy, and Walschaerts motions. Corliss, and later, poppet valve gears had separate admission and exhaust valves driven by trip valve or cams profiled so as to give ideal events; most of these gears never succeeded outside of the stationary marketplace due to various other issues including leakage and more delicate mechanisms.
Steam turbines provide direct rotational force and therefore do not require a linkage mechanism to convert reciprocating to rotary motion. Thus, they produce smoother rotational forces on the output shaft. This contributes to a lower maintenance requirement and less wear on the machinery they power than a comparable reciprocating engine.
The main use for steam turbines is in electricity generation (in the 1990s about 90% of the world's electric production was by use of steam turbines) however the recent widespread application of large gas turbine units and typical combined cycle power plants has resulted in reduction of this percentage to the 80% regime for steam turbines. In electricity production, the high speed of turbine rotation matches well with the speed of modern electric generators, which are typically direct connected to their driving turbines. In marine service, (pioneered on the Turbinia), steam turbines with reduction gearing (although the Turbinia has direct turbines to propellers with no reduction gearbox) dominated large ship propulsion throughout the late 20th century, being more efficient (and requiring far less maintenance) than reciprocating steam engines. In recent decades, reciprocating Diesel engines, and gas turbines, have almost entirely supplanted steam propulsion for marine applications.
Virtually all nuclear power plants generate electricity by heating water to provide steam that drives a turbine connected to an electrical generator. Nuclear-powered ships and submarines either use a steam turbine directly for main propulsion, with generators providing auxiliary power, or else employ turbo-electric transmission, where the steam drives a turbo generator set with propulsion provided by electric motors. A limited number of steam turbine railroad locomotives were manufactured. Some non-condensing direct-drive locomotives did meet with some success for long haul freight operations in Sweden and for LMS Turbomotive, but were not repeated. Elsewhere, notably in the United States, more advanced designs with electric transmission were built experimentally, but not reproduced. It was found that steam turbines were not ideally suited to the railroad environment and these locomotives failed to oust the classic reciprocating steam unit in the way that modern diesel and electric traction has done.
By the 1840s, it was clear that the concept had inherent problems and rotary engines were treated with some derision in the technical press. However, the arrival of electricity on the scene, and the obvious advantages of driving a dynamo directly from a high-speed engine, led to something of a revival in interest in the 1880s and 1890s, and a few designs had some limited success..
Of the few designs that were manufactured in quantity, those of the Hult Brothers Rotary Steam Engine Company of Stockholm, Sweden, and the spherical engine of Beauchamp Tower are notable. Tower's engines were used by the Great Eastern Railway to drive lighting dynamos on their locomotives, and by the Admiralty for driving dynamos on board the ships of the Royal Navy. They were eventually replaced in these niche applications by steam turbines.
In more modern times there has been limited use of steam for rocketry – particularly for rocket cars. Steam rocketry works by filling a pressure vessel with hot water at high pressure and opening a valve leading to a suitable nozzle. The drop in pressure immediately boils some of the water and the steam leaves through a nozzle, creating a propulsive force. Steam Rockets Tecaeromax
Ferdinand Verbiest's carriage was powered by an aeolipile in 1679.
Failure modes may include:
Steam engines frequently possess two independent mechanisms for ensuring that the pressure in the boiler does not go too high; one may be adjusted by the user, the second is typically designed as an ultimate fail-safe. Such traditionally used a simple lever to restrain a plug valve in the top of a boiler. One end of the lever carried a weight or spring that restrained the valve against steam pressure. Early valves could be adjusted by engine drivers, leading to many accidents when a driver fastened the valve down to allow greater steam pressure and more power from the engine. The more recent type of safety valve uses an adjustable spring-loaded valve, which is locked such that operators may not tamper with its adjustment unless a seal is illegally broken. This arrangement is considerably safer.
Lead may be present in the crown of the boiler's firebox. If the water level drops, such that the temperature of the firebox crown increases significantly, the lead melts and the steam escapes, warning the operators, who may then manually suppress the fire. Except in the smallest of boilers the steam escape has little effect on dampening the fire. The plugs are also too small in area to lower steam pressure significantly, depressurizing the boiler. If they were any larger, the volume of escaping steam would itself endanger the crew.
The Rankine cycle is sometimes referred to as a practical Carnot cycle because, when an efficient turbine is used, the TS diagram begins to resemble the Carnot cycle. The main difference is that heat addition (in the boiler) and rejection (in the condenser) are Isobaric process (constant pressure) processes in the Rankine cycle and isothermal (constant temperature) processes in the theoretical Carnot cycle. In this cycle, a pump is used to pressurize the working fluid which is received from the condenser as a liquid not as a gas. Pumping the working fluid in liquid form during the cycle requires a small fraction of the energy to transport it compared to the energy needed to compress the working fluid in gaseous form in a compressor (as in the Carnot cycle). The cycle of a reciprocating steam engine differs from that of turbines because of condensation and re-evaporation occurring in the cylinder or in the steam inlet passages.
The working fluid in a Rankine cycle can operate as a closed loop system, where the working fluid is recycled continuously, or may be an "open loop" system, where the exhaust steam is directly released to the atmosphere, and a separate source of water feeding the boiler is supplied. Normally water is the fluid of choice due to its favourable properties, such as non-toxic and unreactive chemistry, abundance, low cost, and its thermodynamic properties. Mercury is the working fluid in the mercury vapor turbine. Low boiling hydrocarbons can be used in a binary cycle.
The steam engine contributed much to the development of thermodynamic theory; however, the only applications of scientific theory that influenced the steam engine were the original concepts of harnessing the power of steam and atmospheric pressure and knowledge of properties of heat and steam. The experimental measurements made by Watt on a model steam engine led to the development of the separate condenser. Watt independently discovered latent heat, which was confirmed by the original discoverer Joseph Black, who also advised Watt on experimental procedures. Watt was also aware of the change in the boiling point of water with pressure. Otherwise, the improvements to the engine itself were more mechanical in nature. The thermodynamic concepts of the Rankine cycle did give engineers the understanding needed to calculate efficiency which aided the development of modern high-pressure and -temperature boilers and the steam turbine.
The historical measure of a steam engine's energy efficiency was its "duty". The concept of duty was first introduced by Watt in order to illustrate how much more efficient his engines were over the earlier Newcomen designs. Duty is the number of foot-pounds of work delivered by burning one bushel () of coal. The best examples of Newcomen designs had a duty of about 7 million, but most were closer to 5 million. Watt's original low-pressure designs were able to deliver duty as high as 25 million, but averaged about 17. This was a three-fold improvement over the average Newcomen design. Early Watt engines equipped with high-pressure steam improved this to 65 million.John Enys, "Remarks on the Duty of the Steam Engines employed in the Mines of Cornwall at different periods", Transactions of the Institution of Civil Engineers, Volume 3 (14 January 1840), p. 457
The Carnot cycle, a theoretical ideal thermodynamic cycle, sets the limit of a steam engine's efficiency. Carnot cycle describes a system of two thermal reservoirs with heat transferred between them. In a steam engine part of the heat transferred is converted into mechanical work. The greater the difference in temperature between the two reservoirs, the more efficient the engine. One way of increasing the difference is by using superheater.
The efficiency of a Rankine cycle is usually limited by the working fluid. Without the pressure reaching supercritical levels for the working fluid, the temperature range over which the cycle can operate is small; in steam turbines, turbine entry temperatures are typically (the creep limit of stainless steel) and condenser temperatures are around . This gives a theoretical Carnot efficiency of about 64% compared with an actual efficiency of 42% for a modern coal-fired power station. This low turbine entry temperature (compared with a gas turbine) is why the Rankine cycle is often used as a bottoming cycle in Combined cycle power stations.
One principal advantage the Rankine cycle holds over others is that during the compression stage relatively little work is required to drive the pump, the working fluid being in its liquid phase at this point. By condensing the fluid, the work required by the pump consumes only 1% to 3% of the turbine (or reciprocating engine) power and contributes to a much higher efficiency for a real cycle. The benefit of this is lost somewhat due to the lower heat addition temperature. , for instance, have turbine entry temperatures approaching . Nonetheless, the efficiencies of actual large steam cycles and large modern simple cycle gas turbines are fairly well matched.
In practice, a reciprocating steam engine cycle exhausting the steam to atmosphere will typically have an efficiency (including the boiler) in the range of 1–10%. However, with the addition of a condenser, Corliss valves, multiple expansion, and high steam pressure/temperature, it may be greatly improved. Historically into the range of 10–20%, and very rarely slightly higher. A modern, large electrical power station (producing several hundred megawatts of electrical output) with steam reheat, economizer etc. will achieve efficiency in the mid 40% range, with the most efficient units approaching 50% thermal efficiency.
It is also possible to capture the waste heat using cogeneration in which the waste heat is used for heating a lower boiling point working fluid or as a heat source for district heating via saturated low-pressure steam.
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