4 Ton High-Capacity 690V Electric Boiler – ELECTROMAX (EM-2574 Series)
The ELECTROMAX 4000 KG/HR (4 Ton) 690V Electric Boiler represents the peak of industrial electrification for high-demand steam applications. As global industries move toward carbon neutrality, this high-capacity unit offers a zero-emission alternative to traditional multi-ton fossil fuel boilers. Specifically engineered to operate on a 690V power supply, this model is designed for heavy-duty industrial grids, allowing for higher power density and reduced current load compared to standard voltage systems.
The EM-2574 (4 TPH) model is a horizontal, shell-and-tube package boiler built to the most exacting standards of the Indian Boiler Regulations (IBR). For facilities requiring a massive, steady flow of high-pressure dry saturated steam—such as large-scale chemical plants, textile mills, and pharmaceutical complexes—the 4 Ton ELECTROMAX provides an efficient, silent, and incredibly safe solution.
Maximize Your Production: The 4 Ton 690V Advantage
Transitioning to a 4000 KG/HR electric system allows your facility to generate massive steam volumes while drastically simplifying your plant infrastructure. The 690V configuration is particularly advantageous for high-capacity units, as it allows for more efficient electrical distribution and smaller cable sizes for the same power output.
| Factor | 4 Ton 690V EM Series Advantage | Industrial Impact |
|---|---|---|
| Massive Steam Volume | Consistent 4000 KG/HR output for large-scale industrial processes. | Powers entire production floors or large-scale refinery operations. |
| 690V High-Efficiency Grid | Reduced amperage compared to 415V systems, leading to lower heat loss in cables. | More efficient power distribution and reduced electrical infrastructure costs. |
| 98% Thermal Efficiency | Near-total conversion of electrical energy to steam heat. | Eliminates the 20-30% energy loss typical of fuel-fired boiler chimneys. |
| Certified IBR Safety | Robust construction with government-approved design and inspection. | Peace of mind with mandatory safety certifications for high-capacity vessels. |
| Zero Environmental Impact | No chimney, no smoke, no NOx/SOx, and no carbon taxes. | Future-proofs your facility against tightening emission regulations. |
Technical Excellence & Build Quality
The 4 Ton (4000 KG/HR) ELECTROMAX is a marvel of thermal engineering, designed to maintain structural integrity under the intense thermal cycling of high-output steam generation.
- Advanced 690V Heating System: Utilizing high-voltage ceramic bobbin heaters, the system is optimized for industrial grids. These heaters are submerged directly in the water for instantaneous heat transfer, ensuring that the 4-ton output is maintained even under fluctuating demand.
- Heavy-Duty Pressure Vessel: Constructed from premium IBR-grade SA 516 Gr. 70 boiler-quality steel. Every weld undergoes 100% radiographic testing to ensure it can safely handle sustained working pressures of 10.54 kg/cm² and above.
- Precision Thyristor Control: At 4 tons per hour, power management is critical. Our sophisticated thyristor-based control systems modulate the electrical load with surgical precision, switching heating stages on and off to match the exact steam requirement of the plant.
- Smart Monitoring (Industry 4.0): The EM-2574 comes standard with PLC-based automation and a touch-screen HMI. It features remote monitoring capabilities, allowing plant managers to track steam production, energy efficiency, and maintenance alerts from a central control room.
Operating Range
- Capacity: 4000 KG/HR (4 Ton)
- Fuel: Electric Power (690V, 3-Phase, 50/60 Hz)
- Working Pressure: 10.54 Kg/cm² to 21 Kg/cm²
- Efficiency: 98% ± 2%
- Design: Horizontal Shell & Tube Package Boiler
Technical Specifications
| Specification | Unit | EM-66 | EM-132 | EM-192 | EM-258 | EM-324 | EM-384 | EM-522 | EM-648 | EM-963 | EM-1287 | EM-1602 | EM-1926 | EM-2574 | EM-3204 | EM-4050 |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| General | ||||||||||||||||
| Steam Output (at 100°C) | Kg/hr | 100 | 200 | 300 | 400 | 500 | 600 | 800 | 1000 | 1500 | 2000 | 2500 | 3000 | 4000 | 5000 | 6000 |
| Working Pressure | Kg/cm² | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 | 10.54 |
| Steam Temperature | °C | 183 | 183 | 183 | 183 | 183 | 183 | 184 | 185 | 185 | 185 | 185 | 185 | 185 | 185 | 185 |
| Input Power Required | kW | 66 | 132 | 192 | 258 | 324 | 384 | 522 | 648 | 963 | 1287 | 1602 | 1926 | 2574 | 3204 | 4050 |
| Steam Outlet | mm | 20 | 25 | 25 | 25 | 40 | 40 | 50 | 50 | 80 | 80 | 80 | 100 | 100 | 125 | 125 |
| HTA | m² | 3.5 | 7.01 | 10.2 | 13.71 | 17.22 | 20.41 | 23.08 | 28.65 | 42.58 | 56.91 | 70.93 | 89.26 | 113.97 | 141.86 | 180 |
| Input Power: 415 V – 3 Phase 50 Hz | Fuel: Electric Power | ||||||||||||||||
| Boiler Efficiency | % | 98±2 | 98±2 | 98±2 | 98±2 | 98±2 | 98±2 | 98±2 | 98±2 | 98±2 | 98±2 | 98±2 | 98±2 | 98±2 | 98±2 | 98±2 |
| Electrical Load | ||||||||||||||||
| Feed Water Pump | HP | 1.00 | 1.00 | 1.00 | 1.00 | 1.50 | 1.50 | 2.00 | 2.00 | 3.00 | 3.00 | 4.00 | 4.00 | 4.00 | 6.00 | 6.00 |
| Input Heater Power | HP | 88.00 | 176.00 | 256.00 | 344.00 | 432.00 | 512.00 | 696.00 | 864.00 | 1284.00 | 1716.00 | 2136.00 | 2568.00 | 3432.00 | 4272.00 | 4110.00 |
| Total Electric Load | HP | 89.00 | 177.00 | 257.00 | 345.00 | 433.50 | 513.50 | 698.00 | 866.00 | 1287.00 | 1719.00 | 2140.00 | 2572.00 | 3436.00 | 4278.00 | 4116.00 |
| NOTE: In view of constant endeavors to improve our products, we reserve the right to alter or change above specifications without prior notice. | ||||||||||||||||
Note: For 690V applications, switchgear and cable requirements are optimized for lower current draw compared to 415V models.
Key Features of the 4 Ton ELECTROMAX 690V
- Instantaneous Response: While a 4-ton coal boiler might take over an hour to reach pressure, the EM-2574 reaches working pressure in 15–20 minutes, allowing for much faster production startups.
- No Fuel Logistics: Eliminates the need for coal yards, oil storage tanks, or gas pipelines. This frees up significant land area for additional production lines.
- Modular Reliability: The heating elements are arranged in independent banks. If one bank requires maintenance, the boiler can continue to operate at partial capacity, ensuring your plant never goes completely dark.
- Silent Industrial Power: Unlike the roar of high-capacity burners and blowers, the 4 Ton ELECTROMAX operates almost silently, significantly improving the work environment for plant operators.
- Multi-Level Safety: Equipped with dual IBR safety valves, high-pressure trips, and a sophisticated low-water cut-off system that protects the heaters from dry-firing.
Applications for 4-Ton Electric Steam
The 4000 KG/HR ELECTROMAX is specifically designed for high-volume industrial consumers:
- Large Textile & Dyeing Houses: Providing the massive, clean steam volume required for continuous dyeing ranges and fabric finishing.
- Large-Scale Pharmaceuticals: Ideal for facilities with multiple high-capacity sterilizers and fermentation tanks where steam purity and reliability are non-negotiable.
- Chemical Processing Plants: Perfect for high-pressure reactors and large-scale distillation processes where flame-free operation is a safety requirement.
- Edible Oil Refineries: Used in deodorizing and processing sections where a consistent, high-temperature steam supply is vital for product quality.
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