2.5 Ton Medium Voltage Electric Boiler – ELECTROMAX (EM-1602 Series)
The ELECTROMAX 2500 KG/HR Medium Voltage Electric Boiler is a heavy-duty industrial powerhouse designed for large-scale manufacturing facilities that require high-volume, high-pressure steam with zero environmental compromise. As industries shift toward electrification and decarbonization, this 2.5-ton capacity unit offers a robust alternative to traditional coal or oil-fired boilers, delivering massive steam output with a 98% thermal efficiency rating.
The EM-1602 (2.5 TPH) model is a horizontal, shell-and-tube package boiler engineered to handle the rigorous demands of continuous industrial shifts. By utilizing medium voltage configurations and advanced thyristor-based power management, it provides a stable, high-purity steam supply that is essential for critical processes in the chemical, textile, and food processing sectors.
Maximize Your Production: The 2.5 Ton Electric Boiler Advantage
Scaling up to a 2500 KG/HR electric system allows your facility to benefit from high-volume steam generation without the massive infrastructure required by fossil fuel plants. The ELECTROMAX 2.5 Ton series is designed for “plug-and-play” industrial integration.
| Factor | 2.5 Ton EM Series Advantage | Industrial Impact |
|---|---|---|
| High Volume Output | Constant 2500 KG/HR steam generation at consistent pressure. | Supports large-scale production lines and multiple process reactors. |
| Precise Power Control | Step-controlled heating or thyristor modulation for exact steam demand. | Prevents energy waste during partial load periods. |
| Certified Safety | Fully IBR-certified design with radiographic testing of all pressure-bearing welds. | Guaranteed compliance with Indian Boiler Regulations for high-capacity units. |
| Environmental Leadership | Zero onsite CO2, NOx, or SOx emissions; no carbon footprint at the point of use. | Ideal for meeting ESG goals and operating in restricted industrial zones. |
| Operational Simplicity | No fuel procurement, no ash handling, and no specialized fireman required. | Significantly reduces labor overhead and operational complexity. |
Technical Excellence & Build Quality
The 2.5 Ton (2500 KG/HR) ELECTROMAX is built with precision engineering to ensure it survives the high thermal stresses associated with large-capacity steam generation.
- Advanced Heating Architecture: The system employs a modular array of high-grade ceramic bobbin heaters. For a 2.5-ton unit, these modules are distributed to ensure uniform heat transfer throughout the water volume, preventing localized scaling and hot spots.
- Medium Voltage Integration: Designed to interface efficiently with industrial power grids, the EM-1602 utilizes high-performance switchgear and heavy-duty contactors to manage the significant electrical load required for 2.5 tons of steam.
- Superior Pressure Vessel Design: The boiler shell is constructed from high-thickness IBR-grade SA 516 Gr. 70 steel. Every unit undergoes rigorous hydraulic testing at 1.5 times the design pressure to ensure long-term structural integrity.
- Automation & Monitoring: Equipped with a high-end PLC and HMI interface, the boiler provides real-time data on steam pressure, water levels, and energy consumption. This data can be integrated into your factory’s SCADA system for centralized monitoring.
Operating Range
- Capacity: 2500 KG/HR (2.5 Ton)
- Fuel: Electric Power (Medium Voltage / 415V-3Phase-50Hz)
- Working Pressure: 10.54 Kg/cm² to 21 Kg/cm²
- Efficiency: 98% ± 2%
- Steam Quality: High-purity dry saturated steam
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: Custom pressures up to 21 Kg/cm² and superheated steam options are available upon special request.
Key Features of the 2.5 Ton ELECTROMAX
- Rapid Response Technology: Unlike large coal boilers that take hours to reach 2.5-ton capacity, the EM-1602 can go from cold start to full pressure in approximately 15–20 minutes.
- Modular Reliability: Because the heating is provided by multiple independent stages, the boiler can continue to operate even if one element needs replacement, preventing total production shutdowns.
- Zero-Stack Design: No chimney is required. This eliminates the need for expensive ducting, stack monitoring systems, and air pollution control equipment.
- Sophisticated Safety Suite: Includes dual IBR-certified safety valves, redundant low-water cut-off probes, and an emergency stop system integrated into the control logic.
- Quiet Performance: Even at 2.5 tons per hour, the boiler operates with only the slight hum of the feed water pump, making it ideal for facilities near urban or residential areas.
Applications for High-Capacity Electric Steam
The 2500 KG/HR ELECTROMAX is the preferred choice for industries requiring clean, high-volume steam:
- Large-Scale Food & Beverage: For industrial-sized pasteurizers, spray dryers, and large cooking kettles where steam purity is critical.
- Chemical & Fertilizer Plants: Providing precise, high-pressure steam for reactors and distillation columns.
- Textile Dyeing & Finishing: Delivering the massive volume of steam needed for dyeing vats and stenters without the soot associated with coal.
- Refineries & Lubricants: Used in blending and heating processes where flame-free operation is a mandatory safety requirement.
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