Environment-friendly and pollution-free | Quick steam from startup | User-friendly & Low maintenance
The ELECTROMAX 5000 KG/HR (5 Ton) Electric Boiler represents the absolute peak of industrial electrification for high-demand, high-volume steam applications. As global industries accelerate toward carbon neutrality and zero-emission mandates, this massive high-capacity unit offers a clean, uncompromising alternative to traditional multi-ton fossil fuel boilers.
Specifically engineered to operate on heavy-duty industrial grids, this model features a 690V configuration (with 415V options available). By utilizing a higher voltage supply, the system delivers immense power density while drastically reducing the amperage draw—allowing for smaller cable sizes, lower electrical distribution losses, and minimized plant infrastructure costs compared to lower-voltage systems.
The EM-3204 (5 TPH) model is a horizontal, shell-and-tube package boiler built to the most exacting standards of the Indian Boiler Regulations (IBR). For mega-scale facilities requiring a continuous, massive flow of high-pressure dry saturated steam, the 5 Ton ELECTROMAX provides a silent, highly efficient, and incredibly safe solution.
Maximize Your Production: The 5 Ton Advantage
Transitioning to a 5000 KG/HR electric system allows your facility to generate massive steam volumes while completely simplifying your plant logistics.
| Factor | 5 Ton EM Series Advantage | Industrial Impact |
|---|---|---|
| Massive Steam Volume | Consistent 5000 KG/HR output for heavy-duty industrial processes. | Easily powers entire manufacturing complexes or large-scale refinery operations. |
| 690V High-Efficiency Grid | Optimized for medium-voltage grids to dramatically reduce current load (Amps). | Lowers heat loss in cables, simplifying switchgear and electrical setup. |
| 98% Thermal Efficiency | Near-total conversion of electrical energy into high-grade steam heat. | Eliminates the 20-30% energy loss typical of fuel-fired boiler chimneys. |
| Certified IBR Safety | Robust construction with government-approved design, materials, and inspection. | Guarantees complete compliance and peace of mind for high-capacity vessels. |
| Zero Environmental Footprint | No chimney, no smoke, zero NOx/SOx emissions, and no carbon taxes. | Future-proofs your facility against tightening environmental regulations. |
Technical Excellence & Build Quality
The 5 Ton (5000 KG/HR) ELECTROMAX is a marvel of thermal engineering, meticulously designed to maintain structural integrity under the intense thermal cycling of continuous industrial steam generation.
- Advanced Heating System: Utilizing high-capacity, heavy-duty heating bundles, the elements are submerged directly into the water for instantaneous heat transfer. This ensures that the 5-ton output is maintained steadily even during sudden, fluctuating process demands.
- Heavy-Duty Pressure Vessel: Constructed from premium IBR-grade SA 516 Gr. 70 boiler-quality plates. Every single weld undergoes 100% radiographic testing to ensure it can safely handle sustained working pressures from 10.54 kg/cm² up to 21 kg/cm².
- Precision Thyristor Modulation: At a 5000 kg/hr capacity, grid management is critical. Our sophisticated thyristor-based control panels modulate the electrical load with surgical precision, step-switching heating stages on and off to match the exact, real-time steam requirement of the plant.
- Smart Monitoring (Industry 4.0): The EM-3204 comes standard with a high-end PLC-based automation network and an intuitive touch-screen HMI. It features remote monitoring capabilities, allowing plant managers to track steam production, power usage, and safety loops from a central control room.
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 5 Ton ELECTROMAX
- Instantaneous Response: While a 5-ton coal or oil boiler can take over an hour to reach operating temperature, the EM-3204 reaches full working pressure in just 15–20 minutes, vastly cutting down on production downtime.
- Zero Fuel Logistics: Eliminates the massive footprint required for coal yards, oil storage tanks, fuel unloading bays, or gas pipelines. This frees up hundreds of square meters of premium factory space.
- Modular Safeguard Architecture: The heavy-duty heating elements are split into independent banks. If a single bank requires servicing, it can be isolated while the boiler continues running safely at partial capacity, keeping your production line online.
- Silent Power: Unlike the deafening roar of high-capacity fossil fuel burners and forced-draft blowers, the 5 Ton ELECTROMAX operates almost completely silent, vastly improving plant ergonomics and safety.
- Multi-Tiered Safety Interlocks: Features dual IBR certified safety valves, independent over-pressure automatic trips, and a redundant, multi-probe low-water cutoff system that prevents any possibility of dry firing.
High-Volume Industrial Applications
The 5000 KG/HR ELECTROMAX is specifically designed to handle the heavy thermodynamic loads of large industrial consumers:
- Mega Textile & Processing Houses: Delivers a massive, continuous volume of completely clean steam required for stenters, continuous dyeing ranges, and high-speed fabric processing.
- Large-Scale Pharmaceuticals: Ideal for bulk drug manufacturing plants with massive sterilization cycles, distillation columns, and fermentation tanks where steam purity is non-negotiable.
- Chemical & Petrochemical Processing: Offers a completely flame-free, sparking-free heating alternative for hazardous zones, high-pressure reactors, and large-scale distillation units.
- Edible Oil & Food Refineries: Provides the consistent, ultra-clean, high-temperature steam essential for deodorizing, bleaching, and large-scale continuous cooking sections.
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