Industrial boiler heaters provide heat and power to various applications. These include agricultural soil steaming, steam generation, comfort heating, and sterilization. Many industries rely on these heaters as part of large-scale heating systems. Modern-day industrial settings often turn to electric boiler heaters for their needs.
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The design of boilers for large-scale industrial applications depends on several factors. These factors include system size, level of heat required, boiler efficiency, and boiler installation space.
At Wattco, we manufacture boiler heaters in various sizes and dimensions, depending on your industry needs. Our team can also replicate flange heaters for your existing boiler system regardless of manufacturer or model.
There are benefits that you can expect to receive from using electric boiler heaters as part of industrial applications. Let&#;s take a look at these below.
Benefits of Electric Boiler Heaters For Large Sites and Industrial Applications
Electric boilers have become popular for industrial use. They are a flexible option that can be easily integrated into various applications. These heaters also improve equipment life and ensure safe operation. Electric heaters are more efficient at heating water and steam than other alternatives. They are also more environmentally friendly because they meet carbon emission standards.
Energy Efficiency
Energy efficiency for industrial boilers is dependent on the boiler&#;s design. In comparison to boiler heaters that use fossil fuels or gas, electric heaters are one of the most energy-efficient models. Approximately 99% of the electrical energy used is converted into heat. Electric boiler heaters can deliver maximum thermal output while expending minimal energy.
Ease of Maintenance
Electric boiler heaters require less maintenance than other alternatives. These heating systems have very few components. They are designed without heat transfer tubes and do not require burner maintenance. Additionally, as they have zero carbon emissions, this also contributes to lower cost of maintenance fees.
Ease of Installation
Electric boilers are compact devices making them much easier to install than other alternatives. As these devices do not require a chimney stack, flue pipes, or condensate pipes, their installation is quicker and cheaper. This is a significant benefit as part of industrial use, especially if you are restricted on space.
Safety
From a safety point of view, electric boiler heaters are more effective when used as part of large-scale industrial applications. As these systems run on electricity, they offer fewer potential hazards. If an electric boiler heater malfunctions, a trip will be switched that will deactivate the heating system.
Flange and Sheath Material Considerations
As mentioned above, an electric boiler heater can be made in various sizes and specifications depending on the application or your industry&#;s needs. However, there are considerations to keep in mind regarding flange and sheath materials depending on the application.
FLANGE MATERIAL
SHEATH MATERIAL
APPLICATION
STEEL
COPPER
Clean water
Freeze protection
Hot water storage
Solutions not corrosive to copper
STEEL
INCOLOY
Hot water
Steam boilers
Mildly corrosive solutions
STEEL
STEEL
Mildly corrosive liquids
High temperatures
STEEL
STAINLESS
Process water
Soap and detergent solutions
Demineralized/ deionized water
STAINLESS
STAINLESS
Mildly corrosive solutions
STAINLESS
INCOLOY
Severe corrosive solutions
Demineralized water
STEEL
STEEL
Link to Partedon Group
Light oil
Medium oil
STAINLESS
INCOLOY
Food equipment
Get a Quote for an Electric Boiler Heater
Wattco custom manufactures electric heaters for boilers based on the materials, configurations, and settings needed for your specific project. Get in touch with Wattco today to receive an electric boiler heater quote and learn more about this product.
For other types of electric boiler, see Electric boiler
Electric steam boiler on the training ship Golden BearAn electric steam boiler is a type of boiler where the steam is generated using electricity, rather than through the combustion of a fuel source. Such boilers are used to generate steam for process purposes in many locations, for example laundries, food processing factories and hospitals. Although they are more expensive to run than gas-fired or oil-fired boilers they are popular because of their simplicity and ease of use. Because of the large currents required, they are normally run from a three-phase electricity supply. They convert electrical energy into thermal energy with almost 100% efficiency but the overall thermal efficiency is variable, depending on the efficiency with which the electricity is generated.
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The process of creating steam with an electric boiler is fairly simple. Electricity is run through a heating element that acts as a resistor to create heat through resistance. Water from the system or holding tank is then run over or near this hot element in a pipe or tank, heating the water to a suitable temperature, then making the water hot enough to boil and become saturated steam,[1] at which point the saturated steam is transported to wherever it is needed via the steam pipes that exit the body of the electric boiler. Electric steam boilers work in a very similar way to fire heated boilers with the exception of what heats the water.
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Some experts that work with boilers on a day-to-day basis feel that electric boilers are actually superior to fuel heated boilers in a few ways. Those experts say[2] that using electric boilers may actually be cheaper than using a fuel heated boiler, while also possibly being much more environmentally friendly. The electric boilers also require less equipment to be installed than a traditional boiler helping to reduce the high installation costs that will come with a fuel heated boiler. Electric Boilers can fit into smaller areas due to the way they are constructed and the lack of required parts that a fuel heated boiler requires to operate.[2]
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Traditional fuel-heated boilers generally require multiple different parts to operate successfully. In contrast, electric boilers are relatively simple devices. Additionally, because electric boilers do not use complicated forms of heat exchange, electric boilers do not contain many of the potential hazards that are commonly present in a fuel-heated boiler. Electric boilers are also generally easier to maintain because they do not need tube replacement, which fuel-heated boilers often require due to soot and fuel residue, or any of the fire maintenance required for a fuel-heated boiler.[3] Electric boilers also have smaller carbon footprints than their traditional cousins, fuel-heated steam boilers, and require less space overall,[4] making them a good choice for smaller operations that are in need of a boiler.
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Some other possible benefits that should be considered are sustainability, due to their low maintenance requirements; marketability, due to the idea that "green" is better;[3] and safety, because it is not as dangerous to run as a traditional fire heated boiler.
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Electric steam boilers are more efficient than fire-heated boilers because they require less energy to be put into them for operation at capacity. This is because there is little energy lost when the transfer of heat from the heating element to the water occurs, unlike traditional fire heated boilers, where there is a substantial amount of energy loss from the air flow required to supply oxygen to the flame.[2] However, if the electricity is generated by a thermal power plant, then the whole system is less efficient than a fire-heated boiler due to the greater inefficiency of the power plant. Therefore, use of electric boilers can actually consume more fuel if the electricity is generated by burning fuels [citation needed].
Electric steam boilers are more easily marketable (than fire-heated boilers) to people that would use them for small applications, because it can be sold with the idea that it is "green" and therefore much better for the environment than buying and operating a fire heated boiler.[3]
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Electric boilers are sometimes looked down upon by some experts for multiple factors. These factors stem from the fact that the electricity that is used to power electric steam boilers has to be generated somewhere. As well as the use of electricity is its cost, especially considering that most electric boilers require a good deal of electricity to run at efficient and full capacity. Generating the power required to run an electric boiler can create just as much - if not more - pollution/emissions than burning fuel in a traditional boiler.[citation needed] Electricity is expensive, and with expected rises in the price of electricity, the use of it in electric boilers will come with a large price.[3] Although there is an argument that in the event of a power outage or brownout the boiler would become unusable (in comparison to gas boilers), in fact both systems need an external power source to run, such as for pumps and valve operation and control.[5]
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Stultz, S. C. (). Steam: its generation and use. (40 ed., Vol. 1). Barberton: The Babcock & Wilcox Company.
Malek, M. (). Boiler Design. Power boiler design, inspection and repair (). New York: McGraw-Hill.
Junge, S. (). Cost-effective electric boilers.Heating/Piping/Air Conditioning Engineering,81(1), BSE22-BSE26.
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365. doi:10./j.apenergy..09.038.Junge, S. (). Cost-effective electric boilers.Heating/Piping/Air Conditioning Engineering,81(1), BSE22-BSE26
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