Electric steam boiler

An electric steam boiler directly converts electricity into process steam, without burning fossil fuels and therefore without any direct emissions on site.

At the Callens Group, we help companies weigh up the technical and economic case for electric steam production. We engineer solutions tailored to your heat demand and energy infrastructure.

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When is an electric steam boiler worthwhile?

An electric steam boiler – and more specifically a resistance boiler – is a smart choice when you need less than 5 to 10 MW of steam and want to cut back on fossil fuels at the same time.

That being said, electrification has to make technical and economic sense and will largely depend on the available electrical capacity, the cost of electricity, the required steam flow rate and the number of operating hours.

Finally, an electric steam boiler works without local combustion. As a result, there are no flue gases and direct CO2 and NOX emissions on site drop.

Stoomketel Elektrisch Agfa
Callens Elektrische Stoomketel 1

5 reasons to consider electric steam production

  • You want to phase out the use of fossil fuels.
  • You want to lower CO2 and NOX emissions on site.
  • You have sufficient electrical capacity or are considering a grid upgrade.
  • You want to use surplus or green electricity to generate process steam.
  • You want to run the boiler at times when electricity is cheap.

Power

20 kW to 15 MW

Capacity

25 to 10,000 kg/h steam

Connection voltage

400 to 690 V

Design pressure

0.5 to 40 barg

Efficiency

99 %

Technical specifications of electric steam boilers

The technical specifications of an electric steam boiler have to align closely with the needs of your production process. Correct sizing not only ensures a reliable steam supply but also makes the best possible use of the available electrical capacity and delivers maximum efficiency.

Electric steam production has a major impact on your energy management. That is why we look at:

  • Grid capacity
  • Load profiles
  • Available green electricity
  • Future electrification plans

The Callens Group guides you through this technical assessment with a team of experienced thermal technology specialists. That way, you can be sure your steam boiler is perfectly matched to your production process and energy infrastructure.

benefits

Advantages of an electric steam boiler

Since the energy transition, more and more companies are switching to electric steam boilers every year. The big advantage? They produce steam without direct CO2 and NOX emissions and reduce dependence on fossil fuels.

Discover 6 more practical advantages here.

Lower emissions

No combustion in the boiler and therefore no direct flue gas emissions.

Fast controllability

Suitable for processes where steam demand can change quickly.

High efficiency

Electricity is converted into heat very efficiently.

Fewer fossil fuels

Steam production becomes less dependent on natural gas or other fuels.

Putting surplus electricity to good use

Available or cheaper electricity can be converted into process steam.

Less auxiliary equipment

No burner or flue gas system needed, making installation simpler.

Electric steam boiler vs. electrode boiler: what’s the difference?

An electric steam boiler is often confused with an electrode boiler. Both produce steam using electricity, but their operating principles and technical requirements differ.

Callens Elektrische Stoomketel Agfa

Electric steam boiler

In an electric steam boiler, the boiler water is heated by electric resistance elements. That is why we also call it a resistance boiler.

This type of boiler is especially worthwhile at lower power ratings (typically less than 5 to 10 MW), for clean steam applications or where no high-voltage infrastructure available. It is often the logical choice when a high-voltage substation is technically or economically less attractive.

Cargill Haubourdin E boiler 20 MW 30 T 1

Electrode boiler

In an electrode boiler, electric current is passed directly through the water to generate heat. Depending on the type of electrode boiler, the conductivity of the water plays a different role. In a semi-immersed electrode boiler, the electrodes are partly in contact with the boiler water, so its conductivity plays an important role in operation and power control. In a jet-type electrode boiler, water is directed onto the electrodes and the power can be controlled through the water flow. As a result, the requirements for water conductivity are less critical and closer to those of conventional steam installations.

An electrode boiler mainly comes into play at higher power ratings, usually from 5 to 10 MW upward. This solution makes absolute sense when you expect a fast response, for example for aFRR, or when high power has to be compactly integrated when space is at a premium.

Callens Elektrische Stoomketel Onderhoud

Maintenance of your electric steam boiler and 24/7 service

The Callens Group’s maintenance and service team makes sure your installation keeps performing at its best, even after commissioning. With an in-house team of more than 120 service and maintenance technicians, we schedule preventive maintenance in line with the legal and technical requirements of your installation.

On top of that, you can count on fast support whenever an unexpected breakdown occurs. Thanks to our 24/7 standby service, an extensive range of spare parts and the expertise of our service technicians, we carry out interventions quickly and effectively.

Even the best maintained installation can malfunction or shut down unexpectedly. That is why the Callens Group offers various service packages, tailored to the response time and support you need so that can rely on our expertise even in unforeseen situations.

More about our service packages
partnership

Why partner with Callens Group?

60 years of experience in EPCS projects

An independent integrator focused on your specific needs

Flexible project execution

Short decision-making lines and a personal approach

Unique service & maintenance support

With 13 locations, always close by

Projects with electric steam boilers

Lamb Weston 900kgh 22 barg Bergen op Zoom PRJ220144 1
Thermal technology Steam boilers Electrification +2

100% electric steam boiler brings new potato flavors to temperature

Capacity900 kg/h
Operating pressure22 barg
Working pressure16-18 barg
Agfa Gevaert Mortsel Eboiler weerstand 5 MW Danstoker PRJ230202 1
Thermal technology Electrification Electric +2

Electric steam boiler efficiently harnesses surplus electricity

Capacity8 T/h
Power5 MW
Design pressure10 barg
“Maximizing energy efficiency doesn’t start with choosing a technology, but with mapping out your environment and goals.”

Are you feeling the heat from all the possibilities?

Our specialists are happy to help you further.

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Questions? We have the answers.

The main difference lies in how the heat is generated:

A gas-fired steam boiler produces heat by burning natural gas or another fuel.

An electric steam boiler directly converts electricity into heat through electric resistance elements, much like an electric kettle.

As a result, an electric steam boiler produces no direct CO2, NOX or flue gas emissions on site. What is more, there is no need for burners, chimneys or flue gas treatment systems.

That is possible, but it will depend on various technical and economic factors, such as electrical grid capacity, required steam flow rate, operating hours and energy prices. In some situations, an electric steam boiler can fully replace the existing installation. In other cases, it is integrated alongside an existing gas-fired boiler as a combined set-up. That way, you can flexibly switch between different energy sources.

Not sure whether full or partial electrification is feasible? Our specialists will be happy to carry out an initial technical analysis of your steam installation. Make an appointment!

The main points to consider are the available electrical capacity, the grid connection and the quality of the feedwater. Depending on the power rating, a transformer, a high-voltage substation or the reinforcement of your grid connection may be required. Beyond that, the same requirements as for other steam installations apply when it comes to water treatment, feedwater supply, steam consumption and operational reliability. The Callens Group analyzes these parameters during the engineering phase to correctly assess technical feasibility.

Want to know whether your existing infrastructure is suitable for electrification? Contact us to discuss your specific question.

An electric steam boiler produces no direct CO2 emissions on site because no combustion takes place. When the installation is powered by 100 % green electricity, CO2 emissions from steam production can even disappear entirely. The actual CO2 reduction will depend on the type of installation that is being replaced, steam consumption and the source of the electricity used.

Curious how much CO2 your company could cut back on? Our engineers will be happy to make an estimate based on your current steam production.

Electric steam boilers are particularly well suited to converting surplus electricity into usable process steam. This could be self-generated solar energy, cheap electricity during certain market periods or available capacity within flexibility markets. In short, an electric steam boiler allows companies to respond to fluctuating electricity prices and to optimize their energy consumption and related costs.

As an EPCS integrator, the Callens Group takes charge of the entire process: from on-site analysis and engineering to installation and service. That gives you a single point of contact throughout the entire life cycle of your electric steam boiler. You can find out more about the different steps in our workflow here.

In many cases, yes. Electric steam boilers are often added to existing steam plants to electrify part of the steam production or to deal more flexibly with energy prices and emission targets. They can work hand in hand with existing gas-fired steam boilers, combined heat and power units or other heat sources within a hybrid energy system. The most suitable configuration will depend on your consumption profile and the available infrastructure.

Want to know whether an electric steam boiler can be integrated into your existing infrastructure? Our specialists would be happy to look into it for you.

Electric steam boilers are worthwhile for any sector that needs process steam and wants to reduce its CO2 emissions at the same time. They are used, among others, in the food and beverage industry, the pharmaceutical industry, the chemical sector, the textile sector, the paper and cardboard industry and other energy-intensive production environments. Companies with a small to medium steam demand in particular are increasingly opting for an electric steam boiler or resistance boiler.

The main limitation of an electric steam boiler is the required power rating. A resistance boiler is ideal for smaller ratings up to 10 MW. For higher ratings, other boilers such as an electrode boiler are recommended. The required steam capacity is decisive too. The higher the values, the more important it becomes to look at other technologies.

Want to know whether an electric steam boiler is technically worthwhile for your situation? Contact our experts for an exploratory chat.