Hybrid steam boiler

Hybrid steam boilers are a much-sought-after technology because they are a low-threshold step toward fewer emissions. With a single boiler, you respond to fluctuating energy prices, grid capacity and the varying availability of fuels.

The Callens Group finishes its hybrid steam boilers to measure for the highest efficiency. On top of that, we add a control system that switches energy source whenever it makes most sense.

Discuss your challenge

When is a hybrid steam boiler worthwhile?

A hybrid steam boiler only becomes worthwhile when you have access to multiple energy sources. Electricity, natural gas and biogas are the most common, but other residual gases are an option too.

The boiler switches fuel supply based on availability of the energy source (e.g. solar energy), the cost and operational needs.

Companies dealing with fluctuating energy prices, changing grid capacity and upcoming climate requirements are increasingly opting for a hybrid approach.

Decospan Menen VKK 4 T 15 MW PRJ240302 4

5 reasons to consider a hybrid steam installation

  • You want the flexibility to respond to fluctuating energy prices.
  • You have multiple energy sources on site.
  • You want to put electricity surpluses to good use for steam production.
  • You want to lower the CO₂ emissions of your steam supply.

Output

4 to 100 MW

Capacity

25 kg/h to 150 t/h steam

Connection voltage

3 x 400 V

Design pressure

from 0.5 barg to 100 barg

Efficiency

up to 99 %

Technical specifications of hybrid steam installations

In hybrid steam installations, the focus is on the smart integration of different heat sources into a single flexible system.

That’s why our engineers look at your complete energy context:

  • consumption profile
  • operational processes
  • available infrastructure

Based on a thorough analysis, our engineers design a compact system with high efficiency and maximum flexibility.

benefits

Advantages of a hybrid steam boiler

More and more companies are combining different steam technologies to organize their energy consumption more intelligently. Hybrid steam installations make it possible to continuously switch between energy sources and, thus, to optimally respond to changing market conditions, production requirements and sustainability targets.

Fewer fossil fuels

Electrification and optimal use of the available energy sources reduce dependence on fossil fuels.

Flexible energy consumption

The installation automatically chooses the most suitable energy source based on availability, price and heat demand.

Lower energy costs

By switching smartly between electricity, natural gas, exhaust gases or other heat sources, energy cost is optimized.

More operational reliability

Multiple energy sources provide extra security and continuity of the steam supply.

Better grid balancing

Electric steam production can be deployed at moments when electricity is abundant or economically attractive.

Useful use of energy surpluses

A functional, low-maintenance way to put energy surpluses to good use.

What’s the difference between a combined set-up, a dual-fuel boiler and a hybrid steam installation?

These terms are often used interchangeably, but they refer to three different concepts.

Hybrid steam boiler

A hybrid steam installation combines different fuels in a single boiler. The best-known version is the steam boiler with a gas burner combined with electric heating elements. Intelligent control automatically determines which fuel is the best option at any given moment.

Steam boiler in a combined set-up

A combined set-up consists of two or more separate steam boilers, each connected to its own energy source. Together they cover the total steam demand. For example: a gas-fired steam boiler combined with a biogas boiler or a hydrogen boiler.

Dual-fuel boiler

A dual-fuel boiler is a single steam boiler with a single burner that can automatically switch between two fuels — think natural gas and (bio-)oil.

20260115 Proud Calliërs service 10

Maintenance of your hybrid 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.

You can also count on fast support whenever an unexpected breakdown occurs. Thanks to our 24/7 on-call 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, even in unforeseen situations, you can count on our expertise.

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

Schermafbeelding 2026 08 28 100631
“Maximizing energy efficiency doesn’t start with choosing a technology, but with mapping out your environment and goals.”

Projects with hybrid steam installations

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

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.

Contact

Questions? We have the answers.

A hybrid steam boiler combines different technologies for steam production within a single steam boiler. Typically, this involves a combination of electricity and natural gas as the energy source. Thanks to intelligent controls, you can automatically switch between the different energy sources, depending on heat demand, energy prices and energy availability.

The switchover happens fully automatically via intelligent control. It takes account of parameters such as energy prices, heat demand, available output, grid capacity and any sustainability targets. This way, the installation produces steam at any moment via the energy source that is the most attractive.

Yes. By flexibly switching between different energy sources, the installation can respond to fluctuating energy prices. When electricity is available at a favorable price, more can be produced electrically. When another heat source is economically more attractive, it takes over. As a result, the total energy cost of your steam production can be significantly optimized. Curious what savings a hybrid steam installation could deliver at your site? Our engineers will be glad to look into it with you.

A hybrid steam installation makes it possible to gradually phase out the share of fossil fuels without jeopardizing operational reliability. By making more use of electricity or other available energy sources, CO₂ emissions can be significantly reduced. The actual emission reduction will depend on the chosen configuration, consumption profile and the energy sources used.

Absolutely. A CHP unit produces electricity and heat simultaneously. That electricity can be used for electric steam production, while the heat is used directly within the process. By combining both technologies, you create a particularly efficient energy system that gets maximally capitalizes on the available energy. Want to know more about combined heat and power? Discover our page on CHP units.

For industrial applications, we mainly see combinations of natural gas and hydrogen, natural gas and electricity, natural gas and biogas, and natural gas and syngas. Curious which combination best suits your specific situation? Ask the Callens Group specialists for advice.

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

Hybrid steam installations can play an important role in flexible energy management. When electric steam production is part of the installation, steam production can be matched to the availability and price of electricity, for example. At moments when there is plenty of electricity on the grid or when the electricity price is low, more can be produced electrically. When conditions change, the system can automatically switch to another heat source. This way, the installation not only helps control energy costs, but also contributes to a more stable load on the electricity grid.

The choice of energy source happens fully automatically via intelligent controls. It takes account of various parameters, such as current heat demand, the availability of energy sources, energy prices, grid capacity and any sustainability targets. Based on this data, the control system continuously determines which energy source is the most favorable one.

To reduce the emissions of a processor of premium wood, Callens delivered a hybrid steam boiler installation that flexibly responds to fluctuating energy prices. The installation combines steam production on natural gas with electric steam generation. This makes it possible to quickly switch to the most cost-effective and sustainable energy source. With a total capacity of 6.3 tons of steam per hour, the installation also leaves room for future growth. Variable-speed pumps ensure lower energy consumption, constant steam quality and less wear and tear. An economizer recovers heat from the flue gases and increases efficiency to 95 %. During the conversion, a temporary rental boiler guaranteed an uninterrupted production process. More details:

[ CTA – project inquiry ]