Advantages of an electrode boiler

Industrial electrode boilers, or e-boilers for short, are among the most efficient technologies for electric steam production. They directly convert electricity into heat, with efficiencies above 99 %. The result? Reliable steam, with far fewer CO2 emissions.

Want to electrify your steam production while keeping a grip on costs and flexibility? Then an electrode boiler opens up plenty of opportunities.

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When is an electrode boiler worthwhile?

An e-boiler is especially worthwhile when you need large volumes of steam or hot water and want to reduce your dependence on fossil fuels at the same time.

Thanks to their high power range (4 to 70 MW), fast controllability and exceptional efficiency, electrode boilers are particularly well suited to energy-intensive production environments.

On top of that, they respond effortlessly to fluctuating electricity prices and to flexibility and imbalance markets.

Electrode boilers often work well in combination with (existing) gas-fired installations, combined heat and power units or other thermal technologies.

Industriele stoomketel elektrodeboiler

6 reasons to consider electric steam production

  • You want to drastically lower the CO2 emissions of your steam production.
  • You have a high-voltage connection.
  • You have a large, continuous heat demand.
  • You want to flexibly respond to electricity prices.
  • You want to valorize surplus or green electricity.
  • You are considering taking part in flexibility or imbalance markets.
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Power

4 to 70 MW

Capacity

up to 100 t/h steam

Connection voltage

6 to 36 kV

Design pressure

up to 70 barg

Efficiency

> 99 %

Technical specifications of electrode boilers

Electrode boilers are not just about power, but about the wider energy context. The correct configuration will depend on:

  • steam demand
  • available electrical capacity
  • water quality
  • grid connection
  • the dynamic energy market

Based on this analysis, our engineers develop a solution that is not only technically sound but one that also pays off strategically.

benefits

Advantages of an electrode boiler

Electrode boilers are quickly gaining popularity among companies that want to electrify their steam production without sacrificing capacity or flexibility. Thanks to their high power ratings, exceptional efficiency, fast controllability and many other benefits, they are the business for energy-intensive production environments.

Lower CO₂ emissions

No local combustion and therefore no direct CO₂, NOx or flue-gas emissions.

Fast controllability

Can start up within minutes and respond very quickly to changing heat demand.

High efficiency

Virtually all electrical energy is converted into usable heat.

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.

Compact footprint

No burner or flue gas system needed, so an e-boiler takes up limited space.

Electrode boiler vs. electric steam 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.

Elektrische stoomketel weerstandsketel zw

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 there is no high-voltage infrastructure. It is often the logical choice when a high-voltage substation is technically or economically less attractive.

Elektrische stoomketel elektrodeboiler zw

Advantages of an 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 via the water flow. As a result, the water conductivity requirements 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 is ideal when you expect a fast response, for example for FCR or aFRR, or when high power has to be compactly integrated into a limited space.

Service elektrische stoomketel

Maintenance of your electrode 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 you can rely on our expertise even in unforeseen situations.

More about our service contracts
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“Maximizing energy efficiency doesn’t start with choosing a technology, but with mapping out your environment and goals.”
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 electrode boilers

Eboiler 4
Thermal technology Electrode boilers Steam boilers +2

E-boilers combine increased production with lower CO₂ emissions

Capacity2 x 5 MW 
Connection voltage15 kV
Cargill Haubourdin E boiler 20 MW 30 T ZW
Thermal technology Electrification Electrode boilers +2

Combination of e-boiler and gas boiler modernizes starch factory

Capacitye-boiler: 20 MW 
gas boiler: 20 MW
Working pressure35 barg

Discuss your challenge or project with our experts

Would you like to explore which solution is suitable for your specific project?

Our engineers are happy to think along with you, from initial exploration to concrete engineering.

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FAQ

Questions? We have the answers.

Both technologies produce steam using electricity, but they work on a different principle. An electric steam boiler heats the water via electric resistance elements, much like an electric kettle. An electrode boiler uses the water itself as a conductor, with the electric current running directly through the water. This makes electrode boilers particularly well suited to high power ratings and high steam capacities. Electric steam boilers are generally used up to about 5 to 10 MW, while electrode boilers are often applied from that power level upward.

That is possible, but it will depend on various technical and economic factors: available electrical grid capacity, required steam flow rate, operating hours and energy prices all play an important role. 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 hybrid solution. That way, you can flexibly switch between different energy sources.

Not sure whether full or partial electrification is feasible? Our specialists would be happy to carry out an initial technical analysis of your steam installation. Feel free to make an appointment.

An electrode boiler is among the fastest controllable steam technologies on the market. Its power can be adjusted to the current electricity price, available grid capacity or your production process’s heat demand within minutes. Thanks to intelligent controls, developed by the Callens Group’s own E&I department, the installation automatically responds to price fluctuations, available green electricity and signals from flexibility markets. That way, you produce steam when it is most worthwhile in energy and economic terms.

An e-boiler produces no direct, local emissions because no combustion takes place. With 100 % green electricity, CO2 emissions can even be brought down to zero. 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 would be glad to make an estimate based on your current steam production.

Because electrode boilers are usually used with higher power ratings, companies generally have a medium or high-voltage connection. Depending on the power rating, additional transformers, switchgear or grid reinforcements may be needed. Water quality, feedwater treatment, steam consumption and operational reliability also remain important points of attention during the design of the installation.

Wondering whether your existing infrastructure is suitable for an electrode boiler? Our experts would be happy to look into it with you.

Yes. When more electricity is temporarily available through your own production or favorable market conditions, an electrode boiler can efficiently convert this energy into steam. In this way, the electrode boiler not only acts as a heat source, but also as a tool to use energy more intelligently and to better absorb the peaks and troughs in electricity consumption.

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.

Thanks to its fast controllability and high power ratings, an electrode boiler is ideal for absorbing peak loads or responding flexibly to fluctuating electricity prices. That is why, in many industrial settings, an e-boiler is used as a complement to existing installations rather than as a full replacement. For example, the electrode boiler can temporarily supply extra steam when it is economically attractive, while other installations continue to carry the base load.

Want to know how you can put an electrode boiler to work in your current production environment? Ask our experts.

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.

For a pharmaceutical company, the Callens Group delivered an installation with two electrode boilers of 5 MW each for the complete steam supply of a new production line. Both installations currently act as a back-up for each other, but thanks to their generous sizing, they can also be run simultaneously to accommodate future production expansions. With an electrical efficiency of 99.9 %, they are also a particularly efficient solution for low-CO2 steam production.

Read more here: https://www.callens.eu/nl/eboilers-of-elektrodeboilers/eboilers-combineren-meer-productie-met-minder-co2