In this article, 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.
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Making steam with an electric boiler
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. Water from the feedtank is then pumped into the pressure vessel, heating the water until it becomes 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 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 systems 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 present in a fuel-fired boiler and will simply trip out if the heating elements are exposed due to low water conditions that can sometimes arise in the operation of steam boilers.
Electric boilers are also 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 flue gas heat losses are present.
Additionally, because electric steam boilers are in some cases fitted with up to 15 electrical elements (dependent on model), they typically have a high turndown (up to 15:1 in the case of Fulton&#;s electric steam boiler range), so can 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 highly-paid plant operatives.
Are you aiming to reduce or eliminate point-of-use emissions from your building? Whether it&#;s due to compliance requirements like BERDO (Building Emissions Reduction and Disclosure Ordinance) in Boston, corporate sustainability goals, or simply the desire to market your products or services as environmentally friendly, electric boilers offer a compelling solution. Let&#;s explore why electric boilers are gaining traction and why Cleaver-Brooks stands out in this arena.
Link to Partedon Group
Model CR Vertical Steam Electric BoilerUnderstanding Electric Boilers:
Electric boilers, including both traditional resistance element boilers and innovative electrode boilers, have been a staple in the industry for decades. However, it&#;s only in recent years, with a heightened focus on green energy and sustainability, that these technologies have seen a surge in popularity. At Frank I. Rounds Company, we affectionately attribute this spike in demand to what we call the &#;Tesla Effect&#; &#; the notion that electric power can revolutionize various industries.
Electricity Rates:
The next critical factor to consider is cost. In some regions, electricity rates are significantly lower than those of gas. For instance, hydropower often offers a more cost-effective option compared to an equivalent quantity of gas in terms of BTU (British Thermal Unit). In such cases, transitioning to electric boilers presents an obvious choice. Not only does it result in a cleaner point-of-use building, but it also reduces operational costs.
Conversely, in areas with higher electricity rates, exploring potential rebates becomes essential to offset expenses. Additionally, residents in BERDO affected zones in Boston must weigh the costs against potential fines. Our team can assist you with a swift cost analysis should you wish to explore further.
It&#;s worth emphasizing the concept of &#;point of use&#; because electric boilers themselves do not emit pollutants at their location. However, it&#;s important to acknowledge that the electricity grid may be powered by a mix of energy sources, including fossil fuels like gas-fired turbines in cogeneration plants. On the bright side, a portion of the power may come from renewable sources such as solar or wind energy.
Many utility companies offer the option to pay a premium for electricity sourced from green sources, although directing power from specific sources can be challenging. Nevertheless, opting for higher-rate green energy often contributes to investments in expanding renewable energy infrastructure.
Considerations and Benefits:
When contemplating a switch to electric boilers, there are several factors to consider. Firstly, assessing whether the electrical grid can support the anticipated power demand is crucial. Additionally, comparing electricity and gas costs, exploring potential rebates, and evaluating the impact on regulatory compliance are essential steps. Electric boilers offer distinct advantages:
Environmental Considerations:
While electric boilers themselves produce no emissions at the point of use, it&#;s important to acknowledge that electricity generation may involve fossil fuel technologies. However, by opting for green energy sources and engaging with utility companies to support renewable energy initiatives, users can mitigate environmental impact.
Maintenance:
Electric Element from a Resistance BoilerMaintaining water quality is crucial for electric boiler performance. While not requiring purified water, maintaining good water quality akin to other commercial and industrial fuel-fired boilers is essential. You want to avoid dissolved solids to prevent any potential coating of the electric elements. Anything that coats the electric element essentially acts like insulation, which will impede the heat transfer from the hot element into the water.
Water Quality Recommendations:
The recommended water quality to prevent corrosion and scale is:
pH8.3 &#; 10.5Iron0.1 PPM maximumAlkalinity<600 PPM maximumChlorides30 mg/liter maximumOxygen0.1 mg/liter maximumSpecific Conductivity mmho/cmTotal Hardness<3 PPM maximum* These guidelines do not include all dissolved materials. For more information about maintaining water quality, contact the equipment manufacturer.Key Steps in Electric Boiler Projects:
In Conclusion:
Electric boilers offer a clean, efficient, and cost-effective solution for reducing emissions and meeting sustainability goals. By partnering with industry leaders and carefully evaluating project parameters, businesses can embark on a path toward greener, more efficient operations.
Our team at Frank I. Rounds is available to provide guidance and support in navigating these considerations to make informed decisions aligned with your goals and priorities. Contact us.
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