Industrial Electric Boilers – 12 kW to 5 MW

Industrial electric boilers are a highly efficient heating system for producing hot water for space heating and/or indirect domestic hot water. An electric boiler uses electric heating elements to generate thermal energy to heat water with high efficiency for space heating in industrial applications or for use in industrial processes. These electric industrial boilers can also produce domestic hot water via an indirect calorifier and environmentally conscious central heating when supplied with carbon neutral electricity.

There has been a large uptake in the popularity of these electric industrial boilers, for your hot water system, if powered by renewable electricity with no carbon emissions, you can eliminate your reliance on fossil fuels and contribute to a cleaner and more sustainable environment with zero emissions.

These large electric boilers are a perfect solution for heating and DHW production via an indirect water heater, being relatively easy to install and not needing any room for fuel storage / fuel supply via gas supply pipelines.

Please note these are high pressure hot water electric boilers (up to 6 bar maximum) for industrial applications and are not an electric steam boiler, and this range is the next step up from our commercial electric boiler range, which can produce a water temperature of 90°C as standard (we cannot produce a higher water temperature than this) and up to 6 bar water pressure.

If you require higher pressures, then you must make a primary circuit and use a plate heat exchanger to separate the two systems and thus the pressures. Like so 

 

 

We do not supply an electric boiler for steam production – i.e., a steam boiler.

Industrial electric boilers have lower installation costs when compared to fossil fuel boilers, as no flue pipe installation is required to remove the products of combustion, as there aren’t any with a high efficiency electric industrial boiler.

All incoming electrical energy is transformed to thermal energy, resulting in an efficiency close to 100% in our industrial and commercial electric boilers.

These electric boilers can aid in reducing the environmental impact with zero emissions, as renewable energy sources produce an increasing amount of electricity that is CO₂ neutral or better, unlike fossil fuels.

Industrial electric boiler efficiency

Industrial electric hot water boilers are generally regarded as having 100% efficiency, as all the incoming electrical energy that goes into the immersion heaters is converted into thermal energy to produce hot water.

Technically, there is an argument that they are 99.9% efficient overall, as there is a minute amount of electricity used to power the control panel on the boiler. Our industrial electric boilers are a reliable source of hot water for space and/or industrial processes heating systems.

Advantages of Electric Boilers

• 100% efficiency of the immersion heaters in these electric-powered hot water boilers
• Robust construction for long-term operation of this industrial electric boiler range
• Easy installation and commissioning.
• You benefit from low servicing and maintenance expenses when it comes to electric boilers, as they require less regular maintenance than a gas or oil boiler. Electric boilers have no moving components as such, whereas other types of boilers have more moving elements that may break down and need maintenance.
• There is no heat exchanger to block up, as there is no combustion chamber in an electric boiler. Electric boilers work by utilising immersion heaters, similar to those used in domestic hot water heaters, but on a larger scale.
• You can get away from fossil fuel as your energy heat source if you use renewable electricity (with zero emissions) and reduce or eliminate your carbon emissions.
• Environmentally friendly, with no combustion gas emissions produced.
• These electric boilers are designed for commercial and industrial heating systems, be they radiators, underfloor heating, or to generate heat for district heating schemes.

Boiler Product Range

• Power output from 30kW to 5 MW – This range of industrial and commercial electric boilers consists of eight models: a 120 kW, 150 kW, 180 kW, 210 kW, 255 kW, 300 kW, 400 kW, and a 500 kW electric boiler. With the ability to cascade up to 10 boilers of various sizes, the largest electric boiler maximum kW output achievable is 5 MW.
• Great boiler output modualtion range – 7:1 for the 120kW model, and 15:1 for the 150kW to 300kW and 400kW and 500kW boilers now have a 30:1 boiler modulation. This energy-saving feature allows close heating system load matching in a highly efficient manner.
• Operating temperature from 20°C to 90°C  water temperature
• Maximum Delta T directly through the boiler is 20°C, and the minimum is 5°C – Outside of these parameters, please hydraulically separate the heating system with a primary heating circuit and a secondary circuit.
• Maximum operating hot water pressure: 6 Bar rated 
• Required Voltage – 400 Volt Three-phase
• 50mm glass wool insulation with sheet metal finish (MO fire classification)
• We use high-quality, screwed, shielded Incoloy immersion heaters within our electric industrial boilers.
• Robust construction
• A safety temperature thermostat with a manual reset set at 110°C (manually adjustable from 90°C to 110°C) is fitted as standard to the electric industrial boilers.

 

Each boiler has multiple immersion heaters used within the boiler, which are either 12 kW or 15 kW in size, that are controlled in groups, giving a high 30:1 (for our 400 & 500 kW) 15:1 modulation ratio (150 kW to 300 kW models) for all but our 120 kW model, which has 7 power output stages, thus 7:1 for this size boiler, and thus improve heating system performance with close heat load matching to the system demand and help you reduce energy costs.

Modulation output steps of our Thermo Max industrial boilers powered by electricity

So, for example, our 500 kW boiler will ramp up and down the output scale of the 30 power output steps from 15kW to 501kW, which is great for high efficiency close heat load matching of the system.

However, the boiler can also be set to a maximum output for each of its power steps and will produce no more than that set level – i.e., if set on power stage 25, which is 411kW of heat output, the boiler will ramp up and down the heating output scale to a maximum of 435kW (thus, the turndown ratio in this example would then be 25:1).

This ensures that our commercial electric boiler range can cover many, many heat output requirements.

Electric Power and Controls Cabinet

Our standard control panel (“X” control panel) set up on our electric boilers is integral to the electric boiler, is fully Modbus type and includes the following:

• Frost protection system – if the water temperature drops below 7°C, the boiler automatically starts to raise the water above 7°C to prevent freezing.
• Inputs:
• Two temperature sensor connections – one for connecting an external temperature sensor for weather compensation and the other for an immersion sensor for control and production of sanitary-grade hot water via an indirect commercial hot water cylinder. Both of these optional sensors are available from us.
• Remote On/off signal
• Safety thermostats switch off.
• 0-10 volt analogue signal for set point temp or percentage of power output
• Outputs: 
• 0-10V temperature signal or percentage of power (power steps)
• Error signal

 

The Modbus TCP protocol uses an RJ45 connection and the Dynamic Host Configuration Protocol (DHCP), a client/server protocol that automatically assigns an IP address to an Internet Protocol (IP) host, along with other relevant configuration information such as the subnet mask and default gateway.

 

Download the Industrial Electric Boilers ThermoMax 120 kW to 500kW Install Manual with X control panel Flexiheat UK

Download the commissioning and maintenance instructions for the Thermo Max range of electric boilers

Accessories for our electric industrial boilers

Essential accessories required for our boilers are a water flow switch or pressure switches or a combined high/low pressure switch to protect the boiler from low (1 bar) or high (6 bar maximum) pressure, a pressure safety valve set at 6 bar, and a drain valve.

These can be fitted into the heating system, or alternatively, the boilers have connections on them for this equipment.

 

 

These connections should be used as a last resort, as they are at the back of the boiler (and out of sight is out of mind to us). Good mechanical engineering practice is to install the safety valve (which can be a pure pressure relief valve or a pressure and temperature relief valve – it’s your choice) in the pipework close to the boiler so that it is in free view. This arrangement makes identification of a safety valve activation easy to see as the water is expelled into the tundish in view. It is also a good idea to have the high/low pressure switch in view.

Replacing a gas or oil fired boiler

Yes, it’s not an issue to replace your existing heating system boilers with an electric boiler; you just need to have the amps required on a three phase electricity supply to power these boilers.

Please contact us

If you need any further assistance, information, to check stock or to obtain prices on the best industrial electric boilers on the UK market, please contact our customer service sales team on 01202 822221 or use our email contact form.