Apr-2024

Engineered solutions for boiler electrification

Helping the world decarbonise one watt at a time: engineered solutions for boiler electrification.

Thermon

Article Summary

Caloritech – electric immersion heaters for multi-fuel boilers: Reducing our carbon footprint is a global responsibility for which Thermon is doing its part in helping the world decarbonise. Local government and utility providers are providing incentives to electrify traditional gas fired boilers. To this extent Thermon has proven success on supplying electric heaters to gas boiler manufacturers who have integrated electric heating into a multi-fuel boiler setup. Our electric flange and screw plug heaters can be configured to a variety of configurations, and can be offered with a SCR control panel. One example of one our success story utilises our electric flange heaters in a multi-fuel setup with gas and oil heating options.

CX flange heaters
EFeatures:
■ Boiler elements available for both Thermon CaloritechTM boilers and boilers of other manufacturers
■ Standard and custom units to customer requirements available
■ Designs for steam boilers and water boilers

CX flange immersion heaters
Caloritech CX Flange heaters are are configurable for multi-fuel boiler applications.

Flange heaters are available in two different series:
CXC series
Caloritech CXC Flange Heaters are used primarily for water heating applications and feature copper sheathed elements silver brazed to a steel flange.
CXI series
Caloritech CXI Flange Heaters are well suited for heating water, especially in hot water and steam boilers, as well as heating mildly corrosive solutions in rinse tanks, spray washers, etc. The heater features incoloy® sheathed elements silver brazed to steel flange.
Features:
■ Available in a standard range of sizes from 2.5” to 14” (ANSI flange dimensions) and up to 135” immersed length, custom lengths and diameters up to 50” are also available
■ Available in a variety of voltages from 208 to 690V
■ Custom flange sizes available
■ Built-in thermostats, thermocouples, thermostat wells and high limits available
■ General purpose, NEMA 4, NEMA 4X & Explosion prrof terminal boxes available
■ CSA, C/US; ATEX, EAC & IEC Ex available.

Screw plug heaters with 1” to 2.5” npt tapered plugs
The application requires the heating element to be fully immersed in the liquid to ensure safe and reliable operation. Electric heating provides close 100% efficiency and is easy to control.

Control panels
Caloritech control panels are designed for automatic control of electric heaters utilising proven concepts and procedures developed from our experience with thousands of installations.

Our panels feature conservative designs with switching devices, fusing and internal wiring derated from the manufacturer’s specified maximum allowable currents.

Type CPA fully packaged control panels are suitable for use in a variety of electric heater installations. The CPA series includes:
■ Type 4 weather resistant enclosures with hinged doors
■ Disconnect switch with door interlock used control circuit transformer with 120V secondary control voltage
■ On-off switch
■ Fused magnetic definite purpose contactor(s)
■ Digital indicating configurable microprocessor based temperature control (Series UT320)
■ Electronic high limit, manual or auto reset
■ Pilot lights for ‘system on’, ‘heat on’, ‘high limit’

Vapor Power electric boilers for a wide range of industries
Vapor Power is a market leader for commercial and industrial boilers.

Electric boilers
Electric hot water boilers
Our electric hot water boilers ensure rapid, reliable heating for both industrial processes and comfort applications, featuring ASME-certified quality, UL-listed components, and robust insulation for maximum performance and safety.

Features:
■ Hot Water from 30 kW to 4,212 kW (102 to 14,321 MBH)
■ Pressure from 30 – 200 PSIG
■ Voltages from 208 – 600 Volts

Electric steam boilers
Vapor Power electric steam boilers are designed to provide fast, efficient, and economical steam for heating and process through the use of electric resistance elements. The boiler controls automatically energise/de-energise steps of elements to maintain the desired steam pressure. All Vapor Power resistance style boilers utilise 70-75 wpsi Incoloy-sheathed elements configured in conservatively sized circuits to allow for overvoltage conditions as great as 10% without adversely affecting the integrity of circuit components.

Features:
■ Steam from 30 kW to 4,680 kW (102 to 15,912 PPH)
■ Pressure from 15 – 2,500 PSIG
■ Voltages from 208 – 600 Volts

Electrode steam boilers
A Vapor Power electrode steam boiler offers a great hybrid boiler room solution, taking advantage of off peak power rates. Fossil fuel fired boilers and the electrode boiler are automatically rotated based on real time power costs, maximising steam plant efficiency. Electrode steam boilers are available in sizes from 800 to 50,000 KW, 2,700 to 167,000 PPH, supply voltage of 4,160 to 15,000 volts, and offer efficiencies greater than 99%.

Features:
■ Steam from 800 kW to 50,000 kW (2,700 to 167,000 PPH)
■ Max. Design Pressure from 450 PSIG
■ Voltages from 4,160 – 15,000 Volts