Recognised as a leader in Joule‑effect electric boiler technology and heat production equipment, the Spanish company ete has solidified its market position over more than four decades, thanks to continuous innovation and involvement in large‑scale projects. The diversity and complexity of the projects in which it is involved reflect its technical capability and commitment to excellence.
In this international project, ete was responsible for the design and construction of an electric boiler for onboard water production on the cargo ship MCT Altair, owned by a German shipowner. The equipment was specifically engineered to meet the unique demands of the maritime sector and received certification from the prestigious naval authority DNV GL (Det Norske Veritas), ensuring compliance with the stringent standards of the maritime industry.
The boiler meets all naval standards and regulations, ensuring safe and efficient operation. The water heating system combines the use of steam at 12 kg/cm² and 190 °C, supported by a tubular coil and electric resistances. These resistances are insulated with magnesium powder and sheathed in Incoloy 825 stainless steel, renowned for its corrosion resistance and long service life.
The boiler body is manufactured from AISI 316L stainless steel, capable of operating at a pressure of 8 kg/cm², ensuring robustness and extended durability. The integrated electrical panel includes all required electrical protections, including a residual current device and a thermal‑magnetic circuit breaker, along with an electronic control system equipped with PT1000 probes and switching relays. This blend of technologies ensures efficient, safe operation that aligns with industry best practices, meeting clients’ quality expectations.
To ensure the optimal performance of the Joule‑effect electric boiler, it is essential to consider various technical, operational, and safety aspects. Below are detailed descriptions of critical components and best practices needed for efficient operation of this equipment:
1. BOILER STRUCTURE
Material Selection: The boiler body is constructed from AISI 316L stainless steel, chosen for its exceptional resistance to corrosion and mechanical stress. This material is particularly suited to marine environments, where saltwater exposure can accelerate corrosion in lesser materials.
Design and Pressure Rating: Designed to operate at a maximum pressure of 8 kg/cm², the boiler’s robust construction ensures longevity and minimises the risk of structural failure. The design rigorously complies with applicable maritime safety standards, ensuring capability under demanding operating conditions.
2. HEATING SYSTEM
Combined Heating Method: The boiler employs a combined heating approach, integrating steam at 12 kg/cm² and 190 °C. This method enhances thermal efficiency, delivering faster heat transfer and more effective temperature control.
Tubular Coil: The inclusion of a tubular coil optimises heat exchange significantly. Its design and layout promote uniform flow, avoiding overheating hotspots that could lead to material fatigue or failure.
Electric Heating Elements: The heating elements are clad in Incoloy 825 stainless steel and insulated with magnesium powder, ensuring efficient heat transfer and protection from harsh environmental factors. This material is recognised for its durability and oxidation resistance, making it ideal for high‑temperature applications.
3. ELECTRICAL SYSTEM
Integrated Control Panel: The electrical panel is designed to include all necessary electrical protections, such as:
• Residual Current Device (RCD): Prevents electric shocks by cutting off power in case of fault.
• Magnetic Circuit Breaker: Protects the system from overloads and short circuits, extending the lifespan of electrical components.
• Electronic Control System: Utilises PT1000 temperature probes for precise monitoring. Switching relays allow automated and efficient operation, optimising the heating process performance.
4. SAFETY AND COMPLIANCE
Regulatory Compliance: All components meet applicable maritime regulations and standards. Certification issued by recognised authorities such as DNV GL (Det Norske Veritas) ensures the equipment meets the highest safety and performance standards.
Safety Mechanisms: The boiler is equipped with multiple safety features, including:
• Safety Valves to release excess pressure and prevent catastrophic failure.
• Pressure Gauges for continuous monitoring of operating pressure, ensuring it remains within safe limits.
• Temperature Safety Controls with automated systems that shut down the boiler if temperatures exceed predefined limits.
5. MAINTENANCE AND INSPECTION PROTOCOLS
Preventive Maintenance Schedule: A strict preventive maintenance plan is essential, including regular inspections, cleaning of heating elements, and safety mechanism checks, to ensure reliable operation.
Operator Training: Comprehensive training programmes should be provided to operators, covering operational procedures, safety protocols, and emergency response, ensuring the team is fully prepared to operate the equipment.
6. ENERGY EFFICIENCY CONSIDERATIONS
Thermal Insulation: The boiler is designed with high-quality thermal insulation to minimise heat loss. This not only improves energy efficiency but also reduces operational costs and extends the equipment’s service life.
Energy Monitoring Systems: Integration of advanced energy monitoring systems allows detailed consumption analysis, helping to identify improvement areas. Real-time data enables process adjustments and waste reduction, while also predicting potential failures before they occur — avoiding unplanned downtime and additional costs.
7. DOCUMENTATION AND RECORDS
Operating Manuals: Detailed operational manuals are essential, including safety instructions, maintenance guidance, and troubleshooting steps. These documents are crucial for consistent operation and to facilitate audits and inspections.
Maintenance Records: Keeping comprehensive logs of maintenance activities, inspections, and operating parameters is vital to monitor performance and plan future upgrades or equipment replacement.
8. ENVIRONMENTAL CONSIDERATIONS
Emissions Control: While electric boilers have a significantly lower environmental impact compared to fossil fuel systems, it is essential to evaluate the electricity source. Prioritising renewable sources such as solar or wind contributes to carbon footprint reduction. Additionally, strategies should be implemented to monitor and minimise emissions associated with electricity generation, ensuring the energy supply does not compromise sustainability goals.
Waste Management: Proper waste disposal procedures must be implemented during boiler operation or maintenance. This ensures compliance with environmental regulations and promotes sustainable practices that minimise environmental impact, including material recycling and the use of biodegradable products.
CONCLUSION
In summary, the successful and industry-aligned operation of an electric boiler using the Joule effect depends on structural integrity, efficient heating systems, robust electrical configurations, strict safety measures, proper operator training, meticulous maintenance, and full regulatory compliance.
These factors not only ensure the effective operation of the boiler but also contribute to the long-term sustainability of the installation. By implementing a holistic approach that incorporates all these elements, companies can achieve both regulatory compliance and a competitive edge in a market that is increasingly focused on sustainability.
ete continues to expand its presence in the global market, reinforcing its reputation as a leader in heating and energy production solutions. In doing so, the company reaffirms its commitment to a more sustainable and technologically advanced future through innovative projects that combine efficiency with environmental responsibility.
