Environment-friendly and pollution-free | Near 100% Thermal Efficiency | Carbon-Free Powerhouse
The ELECTROMAX 6000 KG/HR (6 Ton) Electric Boiler represents the ultra-high capacity tier of industrial electrification. As global corporate mandates push aggressively toward “Net Zero” carbon footprints, this heavy-duty system allows mega-facilities to completely eliminate multi-ton fossil fuel burners without sacrificing a single kilogram of steam performance.
Engineered to integrate seamlessly with heavy-duty Medium-Voltage (690V) grids, the EM-4050 uses a higher electrical potential to supply a massive 4050 kW of continuous thermal output. This high-voltage configuration significantly reduces current draw (amperage), lowering internal system heat loss, simplifying switchgear infrastructure, and reducing cable footprint costs throughout your facility.
Manufactured at our state-of-the-art facility under strict compliance with the Indian Boiler Regulations (IBR), this horizontal shell-type package boiler is a plug-and-play powerhouse built to deliver high-purity dry saturated steam for massive continuous industrial processes.
Maximize Your Scale: The 6 Ton Performance Advantage
Upgrading to a 6000 KG/HR electric setup completely transforms plant logistics by eliminating fuel dependency, reducing space constraints, and streamlining regulatory workflows.
| Operational Factor | 6 Ton EM-4050 Series Advantage | Bottom-Line Impact |
|---|---|---|
| Massive Clean Volumetrics | Continuous 6000 KG/HR high-grade steam output. | Seamlessly drives large-scale distillation, drying, and central process networks. |
| High Power Density (690V) | Engineered for 690V grids to optimize current loading across element banks. | Drastically lowers electrical distribution costs and heavy copper cabling costs. |
| 99% Thermal Efficiency | Converts nearly 100% of electrical energy directly inside the pressure vessel. | Eliminates the 20% to 30% exhaust stack/flue losses typical of gas or oil boilers. |
| Full IBR Compliance | Certified design, premium boiler plate construction, and complete traceability. | Guarantees absolute safety compliance with statutory Indian industrial laws. |
| Zero Site Footprint Chimney | Requires no stack, no draft fans, zero local emissions, and no fuel storage. | Bypasses complex State Pollution Control Board (SPCB) clearances and carbon taxes. |
Heavy-Duty Industrial Architecture
To safely modulate and transfer 4050 kW of electrical power into continuous high-pressure steam, the 6 Ton ELECTROMAX utilizes advanced, multi-tiered structural engineering.
- Premium Submerged Elements: The system uses heavy-duty, corrosion-resistant heating bundles (made from high-grade Incoloy or SS 316L) fully immersed inside the water column. This ensures instantaneous heat transfer, meaning the system can adjust from standby to peak 6-ton capacity in a fraction of the time required by solid-fuel boilers.
- Boiler-Quality Vessel Plates: The pressure hull is constructed exclusively from ultra-durable, IBR-approved SA 516 Grade 70 boiler plates. All longitudinal and circumferential joints are subjected to 100% radiographic inspection to effortlessly withstand working pressures up to 21 kg/cm².
- Thyristorized Power Modulation: Managing 4050 kW requires delicate precision. Our advanced electrical control center features step-less thyristor power controllers that modulate electricity consumption dynamically. It switches heating elements on or off in finely tuned increments to perfectly mimic the real-time steam load of your manufacturing line.
- Next-Gen Touch HMI & PLC Control: The EM-4050 features an intelligent, central processing hub with an interactive touch-screen interface. It allows for automated daily profiling, diagnostic monitoring, and seamless SCADA/DCS integration for modern, smart-factory automation.
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.
Core Safety Interlocks & Safeguards
Safety is engineered directly into every weld and circuit of the 6 TPH ELECTROMAX system:
- Redundant Low-Water Protection: Equipped with dual, independent, high-reliability level sensors that trigger an instant electronic shutdown if water levels drop below safe margins, preventing element dry-firing.
- Over-Pressure Controls: Uses mechanical IBR safety valves alongside precise electronic pressure switches that safely shut off power long before maximum structural design limits are approached.
- Isolated Bank Architecture: The extensive heating array is segmented into independent, isolated sub-banks. In the rare event an element section requires maintenance, it can be electronically isolated so the boiler can continue safely running at partial output.
- Electrical Vault Safety: The central panel features complete short-circuit, over-current, and ground-fault leakage relays to maintain complete electrical isolation between the water vessel and your high-voltage grid supply.
Large-Scale Clean Steam Applications
The 6000 KG/HR capacity tier is tailored specifically to meet the enormous, continuous process requirements of major industries:
- Mega Distilleries & Breweries: Powers mash tuns, boiling kettles, and distillation columns with perfectly clean, taint-free steam.
- Central Pharmaceutical Plants: Supplies zero-contamination steam for large bulk-drug sterilizers, multi-stage evaporation systems, and large cleanrooms.
- Textiles Finishing & Dye Houses: Sustains constant high-volume steam demands for continuous fabric washing, drying ranges, and high-speed stenter frames without depositing any soot or ash on premium textiles.
- Mass Food & Dairy Consolidators: Ideal for huge continuous pasteurization grids, spray drying plants, and clean-in-place (CIP) hot sanitization loops.
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