Industrial steam boilers

With more than 60 years of experience and over 1,000 successfully completed steam projects, the Callens Group is the reliable total partner for industrial steam boilers. From design to installation and service: every steam installation is developed to measure, with maximum focus on performance, energy efficiency and the lowest possible emissions.

Discuss your steam needs

When is a steam installation a good choice?

An industrial steam boiler is a good choice when your process needs high temperatures (from 100 °C), constant heat transfer and a reliable steam pressure.

Processes such as sterilization, pasteurization, cleaning, drying, humidification, process heating or drive power are typical examples of where steam is useful.

Stoomketel Katoen Natie Antwerpen
Callens stoom combiatie 1

Key advantages of an industrial steam boiler:

  • Flexible energy source: steam can be produced with gas, electricity, biogas, hydrogen, syngas or waste streams.
  • High energy efficiency: modern steam boilers reach efficiencies of more than 99 %. Additional techniques such as economizers, air preheaters, condensers and others further increase efficiency.
  • Broadly applicable: steam boilers are suitable for a wide range of processes in diverse sectors such as food, pharmaceuticals, chemicals, textiles, paper, transport, waste processing and construction.
  • Extensive process control: steam boilers can operate at pressures from 0.5 barg to more than 90 barg, allowing them to be precisely matched to the requirements of the production process.
  • Ready for the energy transition: electrification, hybrid configurations and alternative fuels make it possible to gradually make steam production more sustainable without compromising on operational reliability.
Stoomketel Elektrisch Agfa

Which type of steam boiler is best?

The best steam boiler is the one that suits your consumption profile, available energy sources and future plans. These questions will point you in the right direction:

  • Do you want to lower the CO₂ emissions of your steam production or electrify your production environment?
  • Do you want to be able to respond quickly to fluctuating energy prices?
  • Or are there alternative fuels, residual gases, syngas, biogas or waste heat at your site that aren’t used yet, or aren’t used enough?

Our engineers analyze your situation and recommend the best steam solution.

Ask our experts for advice
SOLUTIONS

The Callens Group’s range of steam boilers

From electric steam boilers and electrode boilers to hybrid installations, waste heat recovery boilers and hydrogen boilers: at the Callens Group, we select specific technologies to provide you with a tailor-made solution.

Our industrial steam installations are available with capacities from 25 kg/h to 100 t/h of saturated steam, and we integrate them seamlessly into your production environment.

Electric steam boilers

Electric steam boilers directly convert electricity into steam and are an attractive solution for companies focusing on electrification, renewable energy or CO₂ reduction.

Technical range:

  • Output: 20 kW to 8 MW
  • Capacity: 25 to 10,000 kg/h steam
  • Connection voltage: 10 to 12 kV
  • Design pressure: 0.5 to 30 barg
More about electric steam boilers

Electrode steam boilers

Electrode boilers are designed for larger outputs and industrial applications with a high steam demand. They offer a fast response time, reach efficiencies of up to 99.9 % and are particularly suitable for flexibility markets (such as aFRR) and grid balancing.

Technical range:

  • Output: 4 to 100 MW
  • Capacity: up to 160 t/h steam
  • Connection voltage: 6 to 40 kV
  • Design pressure: 70 barg
More about electrode boilers

Waste heat recovery boilers

Waste heat recovery boilers produce steam from heat that would otherwise be lost via flue gases or process exhaust gases. A waste heat recovery boiler increases the site’s overall energy efficiency and lowers energy costs.

Technical range:

  • Output: 1 to 15,000 kg
  • Capacity: up to 40 t/h steam
  • Design pressure: 0.5 to 70 barg
More about waste heat recovery boilers

Gas-fired steam boilers

Gas-fired steam boilers combine high efficiency with broad applicability and are still the backbone of many industrial production processes.

Technical range:

  • Output: fire-tube boilers up to 40 MW – water-tube boilers up to 100 MW
  • Capacity: fire-tube boilers from 100 kg/h to 60,000 kg/h – water-tube boilers up to 150,000 kg/h
  • Design pressure: fire-tube boilers up to 40 barg – water-tube boilers up to 100 barg
More about gas-fired steam boilers

Biogas-fired steam boilers

Companies that valorize organic waste streams or have their own digestion installation can use the biogas they generate themselves to produce steam and thus reduce their dependence on fossil fuels.

Technical range:

  • Output: fire-tube boilers up to 40 MW – water-tube boilers up to 100 MW
  • Capacity: fire-tube boilers from 100 kg/h to 60,000 kg/h – water-tube boilers up to 150,000 kg/h
  • Design pressure: fire-tube boilers up to 40 barg – water-tube boilers up to 100 barg
More about biogas-fired steam boilers

Syngas-fired steam boilers

Plants that have syngas as a by-product stream or produce it themselves within their process can use it for steam production. This allows them to valorize an existing energy stream, reduce their fossil fuel consumption and lower both their energy costs and their waste streams.

Technical range:

  • Output: fire-tube boilers up to 40 MW – water-tube boilers up to 100 MW
  • Capacity: fire-tube boilers from 100 kg/h to 60,000 kg/h – water-tube boilers up to 150,000 kg/h
  • Design pressure: fire-tube boilers up to 40 barg – water-tube boilers up to 100 barg
More about syngas-fired steam boilers

Hydrogen-fired steam boilers

Gas-fired steam boilers combine high efficiency with broad applicability and are still the backbone of many industrial production processes.

Technical range:

  • Output: fire-tube boilers up to 40 MW – water-tube boilers up to 100 MW
  • Capacity: fire-tube boilers from 100 kg/h to 60,000 kg/h – water-tube boilers up to 150,000 kg/h
  • Design pressure: fire-tube boilers up to 40 barg – water-tube boilers up to 100 barg
More about hydrogen-fired steam boilers

Steam boilers running on liquid waste streams

Gas-fired steam boilers combine high efficiency with broad applicability and are still the backbone of many industrial production processes.

Technical range:

  • Output: fire-tube boilers up to 40 MW – water-tube boilers up to 100 MW
  • Capacity: fire-tube boilers from 100 kg/h to 60,000 kg/h – water-tube boilers up to 150,000 kg/h
  • Design pressure: fire-tube boilers up to 40 barg – water-tube boilers up to 100 barg
More about steam boilers running on liquid waste streams

Steam boiler in a combined set-up

  • A combined set-up brings several technologies together. Gas-fired and electric boilers, for instance, often work together cost-effectively. This builds in extra flexibility.
  • Technical range:
  • Output: fire-tube boilers up to 40 MW – water-tube boilers up to 100 MW
  • Capacity: fire-tube boilers from 100 kg/h to 60,000 kg/h – water-tube boilers up to 150,000 kg/h
  • Design pressure: fire-tube boilers up to 40 barg – water-tube boilers up to 100 barg
More about steam boilers in a combined set-up

Steam boilers with a dual-fuel burner

With a dual-fuel burner, a single boiler can run on two different fuels — think natural gas and (bio-)oil. This means you will never be short of steam, even when fuel availability or fuel prices change.

Technical range:

  • Output: fire-tube boilers up to 40 MW – water-tube boilers up to 100 MW
  • Capacity: fire-tube boilers from 100 kg/h to 60,000 kg/h – water-tube boilers up to 150,000 kg/h
  • Design pressure: fire-tube boilers up to 40 barg – water-tube boilers up to 100 barg
More about dual-fuel steam boilers

Hybrid steam boiler

Hybrid steam boilers are driven alternately by electricity or natural gas. Ideal if you’re looking for a functional, low-maintenance way to use energy surpluses and to tap into grid balancing.

Technical range:

  • Output: up to 40 MW
  • Connection voltage: 3 x 400 V or 3 x 690 V
  • Capacity: 60 t/h
  • Design pressure: 40 barg
More about hybrid steam boilers

Backup steam boilers

With a backup steam boiler, you build in maximum security for critical processes and prevent production standstills during maintenance, failures or peak loads.

Technical range:

  • Output: fire-tube boilers up to 40 MW – water-tube boilers up to 100 MW
  • Capacity: fire-tube boilers from 100 kg/h to 60,000 kg/h – water-tube boilers up to 150,000 kg/h
  • Design pressure: fire-tube boilers up to 40 barg – water-tube boilers up to 100 barg
More about backup steam boilers

(S)APCS boiler cleaning

The (Semi-)Automatic Pipe Cleaning System keeps downstream steam boilers free of corrosion and fouling. This system makes it possible to clean the boiler’s heating surface while it remains in operation.

More about (S)APCS boiler cleaning

Rental boilers

The Callens Group’s rental boilers are a mobile solution for temporary extra steam capacity. They come with all the fittings, so can be up and running quickly during works or peak loads.

Technical range:

  • Output: 350 kW – 20 MW
  • Capacity: 100 kg/h to 30 t/h
  • Design pressure: up to 30 barg
More about rental boilers
THE CALLENS GROUP IN NUMBERS

One partner. 60 years of expertise. Complete peace of mind.

With the Callens Group, you choose a single partner that manages the entire process, from design to maintenance. Our integrated approach combines technical expertise, project experience and a strong service organization.

500+ projects per year

24/7 service and support

400+ qualified team members

60 years of experience in EPCS projects

Always nearby, with 13 locations

Reduce your CO₂/NOx emissions by up to 100 %

Ready for sustainable steam production?

The energy transition is changing the way industrial companies look at steam production. Energy efficiency, CO₂ emissions, NOx emissions and fuel availability weigh ever more heavily in the choice of a steam installation.

The Callens Group helps you make the right choice. Our engineers develop a steam solution that combines operational reliability with sustainability and economic feasibility.

Ask for advice
Scandinavian Tobacco 2x Viessmann 2 T 13b 1
Tiense Suiker hybride stoom 2x15 T 13b PRJ230176 8

Electrification of steam

Electric steam boilers — also known as resistance boilers — and electrode boilers make it possible to produce steam without direct emissions on site. Combined with green electricity, they can make an important contribution to more sustainable industrial processes.

They also offer benefits such as:

  • great efficiency
  • a fast start-up time
  • the ability to respond to grid balancing and flexibility markets

Hybrid steam production

More and more companies are opting for hybrid steam installations where different technologies work together. By combining gas-fired and electric steam production, for example, you create a flexible solution that responds to changing energy prices, grid capacity and sustainability targets.

Thanks to smart controls, the installation automatically switches to the most suitable and cost-effective energy source.

Alternative fuels

Biogas, hydrogen, syngas and liquid waste streams are alternative fuels for industrial steam production that produce fewer emissions than conventional fossil fuels.

The technical feasibility will depend on:

  • on-site availability
  • fuel quality
  • safety
  • emission requirements
  • return on investment

Thanks to our technology-independent approach, you can be sure of the most suitable steam installation.

Exhaust gases and heat recovery

Many industrial processes produce heat that is lost via flue gases or other waste streams. With waste heat recovery boilers and heat recovery systems, this energy can be reused to produce steam.

This lowers your installation’s energy consumption, reduces CO₂ emissions and increases the overall efficiency of your production process.

Fire-tube boilers vs. water-tube boilers

Both fire-tube boilers and water-tube boilers produce industrial steam, but their construction and field of application differ. While fire-tube boilers are the standard for most industrial applications, water-tube boilers offer advantages when high steam pressures, large outputs or a continuous steam demand are required.

Fire-tube boilers

Fire-tube boilers are by far the most widely used type of industrial steam boiler. In this principle, the hot flue gases flow through tubes surrounded by water. Thanks to their large water content, these boilers are particularly robust, experience little thermal stress and can absorb fluctuations in steam demand excellently.

This makes fire-tube boilers the ideal choice for most industrial applications where a reliable, flexible steam supply is key.

Water-tube boilers

In water-tube boilers, the water flows through tubes located in the furnace and the flue gas duct. Because of their smaller water content, these boilers heat up faster and raise the pressure to 90 barg and higher.

Water-tube boilers are particularly suitable for installations with a continuous steam demand, high outputs and applications requiring high pressure, such as power plants, large chemical installations or steam production combined with combined heat and power.

 Fire-tube boilerWater-tube boiler
Operating principleFlue gases flow through tubes in a water vesselWater flows through tubes in the furnace
Typical pressureLow to medium steam pressureUp to 90 barg and higher
Heat-up timeLonger thermal inertiaFast heat-up
Steam draw-offIdeal for varying loadsIdeal for continuous loads
Thermal stressLimitedHigher
Typical applicationsGeneral industrial processesHigh pressure, large outputs, power plants, CHP

Working with the Callens Group means peace of mind, reliability and certainty

An industrial steam installation is an investment for decades. That is why you should choose a partner who both provides the right solution and the service needed to guarantee lasting performance. The Callens Group offers that combination.

At the Callens Group, you have a single point of contact for your entire steam project: from the first analysis to installation, including service and maintenance. This keeps the process clear and reduces the need for separate coordination between different parties.

The Callens Group is not tied to a single brand, manufacturer or technology. This allows us to select the solution that is technically and economically the most attractive for each project. To do so, our engineers take account of energy prices, grid capacity, water quality, emission targets, available space and total cost of ownership to provide you with a solution that integrates perfectly into your production environment.

With more than 120 service and maintenance specialists, the Callens Group has one of the largest service teams. Preventive maintenance, interventions, remote monitoring and an extensive stock of spare parts ensure that your steam installation remains maximally available and that unplanned downtime is kept to a minimum.

The Department of Technology is the Callens Group’s innovation center. Here, new developments in heat technologies are assessed for their technical feasibility and their added value for industrial applications. Only proven technologies ultimately find their way to customers.

With 13 locations across Belgium, the Netherlands and France, we combine the benefits of an international group with the proximity of local teams. This allows us to act quickly.

Projects with industrial steam boilers

Hybride Stoomketels Tiense Suiker 2
Heat technology Steam boilers Hybrid +2

Zero by 2050 is coming closer with hybrid steam boilers

Capacity2 x 15 T/h
Design pressure13 barg
Eboiler 4
Heat technology Electrode boilers Steam boilers +2

E-boilers combine increased production with lower CO₂ emissions

Capacity2 x 5 MW 
Connection voltage15 kV
Decospan Menen VKK 4 T 15 MW PRJ240302 4
Heat technology Steam boilers Hybrid +2

Hybrid power for a volatile energy market

Capacity6.3 T/h (4 T/h + 1.5 MW electric)
Design pressure13 barg

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Questions? We have the answers.

It involves looking at current and future steam demand, peak loads, process requirements, operating hours and any expansion plans. A thorough analysis prevents both oversizing and capacity problems.

Maintenance frequency will depend on the type of boiler, operating conditions and the legal requirements. Regular inspections and preventive maintenance are essential to guarantee the efficiency, safety and service life of the installation.

Bedrijfszekerheid wordt verzekerd door een correcte dimensionering, preventief onderhoud, monitoring, redundantie en indien nodig een back-up stoomketel of tijdelijke huurketel. Bovendien bieden we bij de Callens Group een uitgebreid service- en onderhoudspakket om uw stoominstallatie maximaal te laten renderen. 

A steam boiler converts energy into heat, which is then used to evaporate water into steam. That steam acts as an energy carrier in industrial processes that require a controlled heat transfer.

Depending on the installation, steam can be produced with natural gas, biogas, hydrogen, syngas, liquid waste streams, electricity or recovered process energy. At the Callens Group, we sit down with you to identify the most suitable energy source for your specific situation.

Er bestaan verschillende manieren om de CO2- en/of NOX-uitstoot van een bestaande stoominstallatie te verminderen: door elektrificatie, hybride configuraties, alternatieve brandstoffen, energierecuperatie of de integratie van moderne brandertechnologieën. De meest geschikte aanpak hangt af van uw proces, energieverbruik en duurzaamheidsdoelstellingen. Bespreek de mogelijkheden.  

Steam boilers are used for sterilization, pasteurization, drying, humidification, cleaning, process heating and driving machinery, among other things. They are used in sectors such as food, chemicals, pharmaceuticals, paper, textiles and building materials.

Modern steam boilers reach efficiencies of between 85 % and 99 %, depending on the type of installation, the fuel and the operating conditions. Through heat recovery via economizers, air preheaters, condensers, intercoolers and others, this efficiency can be increased even further.