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Electric steam boilers Vs traditional fuel-fired counterparts

Carl Knight &#; managing director of process steam and heat transfer specialist Fulton &#; looks at the advantages of electric steam boilers versus their traditional fuel-fired counterparts.

Electric steam boilers work in a very similar way to fuel-fired boilers except in the way that the water is heated.

The process of creating steam with an electric boiler is a relatively straightforward one. Electricity is passed through a heating element that acts as a resistor to create heat through resistance. Water from the feedtank is then pumped into the pressure vessel, heating the water enough to boil and become saturated steam at (depending upon the pressure setting controller) typically between 6 and 10 Barg, at which point the saturated steam is available to the process.

Advantages

Some believe that electric steam boilers are superior to fuel-fired steam boilers in a few ways. They believe that using electric boilers may be less expensive than using a fuel-fired boiler in the long term, whilst also possibly being more environmentally friendly.

Using Fulton&#;s portfolio of electric steam boilers as an example, less ancillary equipment is required than a traditional steam boiler, therefore helping to reduce the installation costs that come with a fuel-fired boiler. Electric boilers also generally have a smaller footprint and can therefore fit into smaller areas thanks to the way they are constructed and the lack of ancillaries that a fuel-fired boiler needs to operate.

Possible disadvantages

Electric boilers are sometimes overlooked as a potential solution to steam generation due in part to the higher cost of electricity versus the cost of traditional fuels. To help meet its climate change and air quality targets, in the budget the government announced that it would remove the entitlement to use red diesel from most sectors, including for use in industrial boilers, from April . The tax changes will ensure that most users of red diesel will use fuel taxed at the standard rate for diesel from April . As a result, many companies are now turning to more sustainable methods of generating electricity, including solar or wind generation. These schemes offset, or at least partially offset, the higher fuel costs.

Safety of operation

Traditional fuel-fired steam boilers generally require multiple elements to operate successfully. In contrast, electric boilers are relatively simple devices. Additionally, because electric steam boilers do not use complicated forms of heat exchange, they do not contain many of the potential hazards that are commonly present in a fuel-fired boiler and will simply trip out if elements are exposed due to low water conditions that can arise in the operation of steam boilers.

Electric boilers are also generally easier to maintain because they have no heat transfer tubes, nor require burner maintenance or statutory non-destructive testing (NDT), all of which fuel-fired boilers often require. Electric boilers also have smaller carbon footprints than their counterparts and, again thanks to their small footprints, can often be used for point-of-use steam requirements, making them a good choice for many smaller operations needing steam.

Additional benefits

Another benefit that should be considered is sustainability, thanks to their low maintenance requirements; and marketability owing to their green attributes, in the same manner as electric vehicles are seen as &#;green&#; versus petrol or diesel counterparts.

Electric steam boilers are also more efficient than fuel-fired 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 fuel-fired boilers where there is a substantial amount of energy loss from the air flow required to supply oxygen to the flame.

Additionally, because electric steam boilers can be fitted, in some cases, with up to 15 electrical elements (dependent on model), they have a high turndown (up to 15:1 in the case of Fulton&#;s electric steam boiler range), so are able to modulate efficiently to varying steam loads.

Electric boilers are, as already stated, more efficient, but for large generating capacities are frequently not practical to install due to large supply cables and infrastructure requirements. However, the actual maintenance costs can be up to 50% less than those of fuel-fired steam boilers. Generally, the only major parts that are periodically changed are the electric elements themselves, yet these are often replaced quickly and cost effectively. This balances lower life cycle costs against the high maintenance requirements of fuel-fired boilers, including refractory repairs, 5-year NDT requirements, burner maintenance, flue maintenance and the requirement for highly-skilled and often highlypaid plant operatives.

For additional information please visit www.fulton.co.uk

With manufacturing facilities in the United States, Great Britain and China, Fulton is a global manufacturer of steam, hydronic and thermal fluid heat transfer systems. Backed by over 60 years of research, innovation and experience, Fulton is building on a tradition of success and is focused on improving life through heat transfer solutions.

https://www.linkedin.com/company/fulton-boiler-works-gb-limited/

The hum of the industry works tirelessly due to archaic-looking steam boilers, housing the ultimate in power for their ability to serve many varied applications. Of course, choosing the right boiler is another matter. That can be a tough call, so from A to Z, this now fully SEO-optimized review will help you understand exactly what gas-diesel metallurgy and electric steam boilers bring to your operation.

For more Hot Oil Boilerinformation, please contact us. We will provide professional answers.

At Simon, we realize industrial processes are powered by the mighty force of steam. That is why we manufacture and distribute a vast array of premium gas-diesel and fully automatic electric steam boilers for the empowerment of your commercial operations.

Steam Power &#; the Real Thing

A Basic Understanding
Primarily, a steam boiler is a sort of pressure vessel designed to convert water into steam in pressured form. This, then, went on to be the fuel for many various industries, running from sterilizing equipment in food processing industries down to driving turbines in electricity generation.

Enter the Rivals

Introducing Gas-Diesel and Electric Boilers
Our plot now thickens as we add in the two main competitors: gas-diesel and electric steam boilers. Each has its very recognizable advantages and considerations, making them more applicable for the different industrial settings.

The Gas-Diesel Boiler

Gas-diesel boilers operate due to the combustion of either natural gas or diesel fuel. The resultant hot combustion gases then transfer their heat energy into the water inside the boiler to produce steam.

Advantages are:

Fuel Flexibility: Can cope with fluctuating fuel costs and availability, being able to run on natural gas or diesel fuel.
High Efficiency: The new generation of gas-diesel boilers can achieve high efficiency, above running a fair fraction of the fuel into steam for economic benefit.
Scalability: These boilers come in different sizes, accommodating small and large industrial builds.

Disadvantages:

Emissions: Combustion in the boiler results in air pollution and requires compliance with the clean air act. This also means that proper maintenance of the boiler will ensure performance and lower emissions.
Fuel Costs: Natural gas or diesel prices affect operating costs; any fluctuation can raise or lower the cost of operations.
Best Applications: Applications that have high, varying demand for steam, like manufacturing, chemical processing, and power generation, tend to take full advantage of the flexibility of fuels with a gas-diesel boiler.

The Electric Boiler

Electric boilers directly use electricity to heat the water elements to produce steam without combustion.

Advantages:

Clean Operation: As there are zero emissions from these boilers, they are highly environment-friendly and ideal for strict air quality regulations. They are especially suitable for urban areas where the regulations are more stringent.
Quiet Operation: Electric boilers are noise-free, hugely improving the working conditions for employees.
Low Maintenance: Electric boilers are low maintenance vis-à-vis their gas-diesel counterparts, thereby minimizing any potential downtime and resource utilization.

Disadvantages:

Energy Costs: The cost of the electricity may be more volatile than natural gas or diesel, which would affect operational costs.
Limited Capacity: Electric boilers generally have lower steam output capacities than gas-diesel boilers. They may be unsuitable for very large-volume steam requirements.
Ideal Applications: Food and beverage processing, pharmaceutical manufacturing, and hospitals find electric boilers most ideal due to the priority that the industries give to a clean and quiet operation. The added advantage is their low maintenance requirements.

Selecting Your Ideal Boiler

Some critical factors rest between choosing your gas-diesel and electric boiler:

Industry-specific steam needs: What is your need for steam pressure and volume for your processes? Electric or Gas-Diesel could be more appropriate if that is the case.
Fuel Availability and Pricing: Compare your accessibility to and cost of natural gas, diesel, and electricity. Pick whichever is the cheapest to go with.
Environmental Regulations: There are tighter controls on the quality of air given off in some industries. Electric boilers are tailor-made for applications of this nature.
Future Growth: Consider possible expansion plans. Do you expect the steam requirements to increase in the near future? Go for a scalable boiler.

You Want to Invest in the Right Boiler

Getting the right boiler is basically an investment in the efficiency and sustainability of your industrial operations. With the factors highlighted above, you can go ahead and make an informed decision so that you select the ideal boiler propelling your industrial success.Don&#;t navigate the industrial steam landscape alone! That&#;s why Simon can be a trusted partner who manufactures quality gas-diesel and electric steam boilers. Our expert team can help you choose just the right boiler for your application, so your industrial engine keeps humming along for years to come.