Electrify part of your steam production with an electrode boiler alongside existing gas-fired boilers
For companies that rely on steam-based processes, electrification does not necessarily mean replacing the entire boiler plant. One option is to combine an electrode boiler with the gas-fired boilers already in operation.
This allows part of the steam production to switch to electricity while retaining existing capacity. The key is how the boilers work together: how is the load shared, and how is operation adapted to production requirements and available energy sources?
How do electric and gas-fired boilers work together?
In a combined system, a separate electrode boiler operates alongside one or more fuel-fired boilers. Each boiler uses its own energy source, while contributing to the plant’s overall process steam supply.
The electrode boiler generates heat directly in the water through electrical resistance. Electricity replaces combustion as the means of producing steam, which is then delivered to the plant’s steam system.
The load shared between the boilers must reflect operating conditions. Available electrical capacity determines the electrode boiler’s potential contribution, while steam demand and operating pressure determine the overall capacity required.
The controls must also coordinate the boilers as demand changes. This requires planned integration with the existing control system and steam supply.
Electrification without replacing the entire boiler plant
Adding an electrode boiler makes it possible to electrify part of steam production while keeping existing boilers in service.
The fuel-fired boiler can continue to supply part of the steam demand or provide backup, provided the system is designed and sized for that role. The electrode boiler therefore does not necessarily need to cover the plant’s entire peak steam demand.
This makes combined operation an option for a phased transition. The extent of electrification can be matched to available electrical capacity and the future role of the existing boilers.
However, retaining a gas-fired boiler does not automatically provide full backup capacity. This depends on its output, condition and ability to take over the required load within the necessary time.
Making flexibility work in practice
Having both electricity and gas available gives a company more options for supplying energy to its steam system. The value of that flexibility depends on the specific operating conditions.
Energy prices, grid charges and operating hours should therefore be considered when deciding how to share production between the boilers. On-site electricity generation may also be relevant if it is available when steam is needed.
Electric operation alone does not guarantee lower costs. Investment, electrical connection costs and expected utilisation must all be included in the assessment. Production requirements must also determine how flexibly the system can operate.
An electrode boiler produces steam without combustion, so there are no local combustion-related CO₂ or NOx emissions from the boiler itself. The overall carbon footprint depends partly on the electricity used and how much fuel-fired steam production it replaces.
PARAT IEH alongside existing steam boilers
At AS SCAN, we supply PARAT IEH boilers for industrial steam production. Depending on the system design, the electrode boiler can serve as a process steam boiler, supplement existing boilers or provide backup capacity.
PARAT IEH automatically adjusts its output in response to steam pressure. The water’s electrical conductivity is continuously monitored because it affects boiler output.
In a combined system, these functions must be integrated with the wider steam supply so that the electrode boiler has a clearly defined operating role.
Learn more about our PARAT electrode boiler for industrial steam production, and contact AS SCAN to discuss combining electricity and gas in your steam supply.