In many industrial plants, steam production relies on large, multi-megawatt diesel or oil-fired boilers. These units are robust, capable of meeting the entire steam demand of the facility, but they are not always the most efficient or flexible option for covering peak consumption, start-up periods or one-off needs.
This is where electric steam boilers come into play as auxiliary boilers, a solution increasingly valued by engineers and production managers.
What is an auxiliary boiler
An auxiliary boiler is not designed to cover the entire demand of the plant, but to:
- To cover steam consumption peaks at certain times of the process.
- To provide service during periods of start-up or shutdown of the main boiler.
- Guarantee continuity in case of main boiler failures or maintenance.
- Optimize costs by avoiding the need to start a large boiler for reduced consumption.
In other words, the auxiliary boiler acts as a safety net and operational flexibility, allowing the plant to operate with greater stability and efficiency.
Diagram showing a main oil boiler + an auxiliary electric boiler working in parallel.
Why is an electric boiler perfect as an auxiliary boiler?
Although there are other options, electric boilers stand out as an auxiliary to smaller oil or gas boilers:
Instant start-up
While an oil-fired boiler takes several minutes (or even hours) to come up to speed, an electric boiler can generate steam in a matter of minutes.
Start-up time of the gas boiler vs. an electric boiler.
This makes it possible to cover occasional consumption without the need to have the main boiler permanently on.
Flexible and modulating operation
Electric boilers easily modulate steam production, adapting to highly variable flow rates without loss of efficiency. Therefore, they are perfect for intermittent consumption.
Zero local emissions
In buildings where emission limits or restricted ventilation are already in place, electric power plants do not generate flue gases.
Low maintenance
They do not require burners, fuel tanks or smoke ventilation systems.
Their mechanical simplicity makes them the most practical option for backup operation.
Optimizable operating cost
If the plant has electricity contracts with hourly discrimination or photovoltaic self-consumption surpluses, the electric boiler can take advantage of these moments of cheap electricity to produce steam.
Practical example: plant with 5 MW diesel boiler
Let’s imagine an industrial building that has a 5 MW main oil-fired boiler to supply its entire steam demand.
In periods of low production, the main boiler is not very efficient for small consumption.
During plant start-ups or night operations, keeping it on is an unnecessary expense.
With the installation of a 500 kW auxiliary electric boiler, the plant achieves:
- Cover peaks and starts without the need to turn on the 5 MW boiler.
- Reduce diesel consumption and emissions.
- Save energy costs by taking advantage of cheaper electricity during off-peak hours.
Conclusion: the electric auxiliary steam boiler translates into flexibility and sustainability.
Electric steam boilers, used as auxiliary boilers in industrial buildings, enable companies:
- Reduce consumption of fossil fuels.
- Increase operational flexibility.
- Improve overall energy efficiency.
- Meet environmental objectives without compromising steam supply reliability.
In a context where greater efficiency and decarbonization are increasingly sought, having an electric auxiliary boiler is not an extra expense, but an investment in safety, savings and sustainability.
At Giconmes we help companies to implement steam-based solutions that improve the efficiency, sustainability and profitability of their processes. Contact us and we will help you to design the optimal solution for your installation.