BOILERS, HOT WATER & RADIATORS
The ultimate guide to advanced electric boiler technology
International boiler expert, Robert Presser, Vice President of Acme Engineering, helps industry professionals take advantage of high voltage electrode boilers’ virtually 100% efficient, zero-emission capabilities, providing guidance on selection and installation
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or consulting engineers tasked with planning, designing, and supervising construction projects for a wide range of industries, advanced electric boilers – particularly high voltage electrode boilers – offer
numerous advantages over traditional fossil fuel burning boilers. Due to advances in technology, these boilers can match the capacity (up to 65 MW) and output (270,000 pounds of steam per hour) of traditional gas or oil-fired boilers in a much smaller footprint while converting almost all the energy to heat. These zero-emission, high voltage electrode boilers are used in diverse environments for applications such as centralised heating, power plants, nuclear stations, swing-load balancing, solar/wind energy consumption, and fuel boiler replacement. Today, there is growing interest in utilising a new generation of these boilers as an environmentally friendly decarbonisation solution. Companies across the globe are considering using electric boilers to become carbon neutral in alignment with COP26 UN Climate Change Conference targets. The transition to electric boilers also aligns with goals to achieve Net Zero emissions economy by 2050. Electric boilers are emerging as more
environmentally friendly solutions than traditional gas-fired units that emit not only the notorious greenhouse gases carbon dioxide (CO2) and methane (CH4), but also dangerous nitrogen oxides (NOx), carbon monoxide (CO), and nitrous oxide (N2O), as well as volatile organic compounds (VOCs), sulfur dioxide (SO2), and particulate matter (PM).
Communities and businesses appreciate the eco-friendly nature of ultra-efficient, electric boilers. Without combustion, these boilers are safe, clean, and emission free. The design eliminates many environmental issues associated with fuel burning boilers, such as fuel fumes, fly ash, and large obtrusive exhaust stacks. However, the challenge for consulting engineers is that many have experience with gas-fired boilers but are less familiar with the selection and implementation of advanced electric boilers, especially the high voltage, high-capacity alternatives available today. What consulting engineers most need to understand about electric boiler technology, including its selection, implementation, and benefits. Acme, which has operations in the US, Canada, and Europe, provides state-of-the-art boilers and accessories for some of the world’s most renowned companies including Siemens, Toshiba, Bechel, PG&E, Power & Mine, and Hydro Quebec.
Types of electric boilers
The first factor to consider in selecting an electric boiler is how much capacity will be required by the user, business, or community. Lower voltage (480 KV) electric resistance heating element boilers are economical, compact, reliable sources to produce steam or hot water for industrial use. The units are well suited to supply these resources at lower capacities, from 9 to 3,600 kW. However, there are design limitations when heating element boilers exceed 4MW in capacity, as numerous flanges, elements, contactors, and fuses are typically necessary to function properly. The considerable amperage involved also requires expensive bars for distribution, step-down transformers, and large switch gear. To avoid these complications at capacities of 4MW or higher, high voltage jet type and immersed electrode boilers were developed.
Acme boilers CEJS High voltage electrode boilers like those from Acme Engineering are virtually 100% efficient, with zero-emission capabilities
High voltage electrode boilers
In the high voltage category, electrode boilers consist of two basic types: immersion and water jet. In resistance element type boilers, current flows through a resistance wire, which generates heat. The heat is transferred through the element’s sheaf and into the water by conduction to produce hot water or steam. With the immersed electrode design, electric
current is passed through the water from the electrodes to the counter electrodes [grounded via the vessel’s shell]. The more direct the exposure between counter electrode shield and the electrode, the greater the current draw [amperage] and the more power is produced in hot water or steam. Modern jet type electrode boilers utilise the conductive and resistive properties of water to carry electric current and generate steam. An AC current from the grounded central column to a minimum of one electrode box per phase, using the water as a conductor. Since the water has electrical resistance, the current flow generates heat directly in the water itself. High voltage jet or immersed electrode boilers
directly connect to high voltage supply lines from 4.16 KV - 25 KV. Hot water boilers are filled with treated water to create a closed loop system. The maximum capacity of the boiler can be adjusted by varying the conductivity, which is determined by the temperature and boiler capacity. Typically, a conductivity monitor is installed in the piping and any adjustments are automatically made with chemical treatment. When it comes to installation, consulting
8 BUILDING SERVICES & ENVIRONMENTAL ENGINEER FEBRUARY 2025
engineers need to consider whether there is sufficient high voltage power, and if a new transformer will be required. In addition, it is necessary to ensure that there is sufficient available space to bring in and install the electrode boilers. This includes determining that there is adequate access into buildings and elevators as well as enough clearance through hallways and doors. When space is limited, units such as Acme’s Slim Series resistance boilers units are designed to produce ample hot water while easing conversion and installation with an ability to “squeeze through” narrow passageways and fit into smaller spaces without costly demolition.
The benefits of electric boilers
For consulting engineers considering the use of electric boilers, there are numerous advantages over gas fired units. These include very high energy efficiency and output control, along with increased safety and other benefits.
Energy efficiency
Although traditional gas fired boilers are familiar, the design can be less efficient than modern electric units. Within this category, the energy efficiency of electrode boiler technology offers extraordinarily efficient power-to-heat generation capability. With electrode boilers, almost all the electrical
energy is converted into heat with no stack or heat transfer losses. This level of efficiency is not achievable in fuel-fired steam boilers even when using an economiser.
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