Caldera's electric steam system for industrial sites
The Caldera Storage Boiler supplies saturated steam up to 204°C for industrial processes. It can connect into a site’s existing steam network, or be used in new builds. It delivers steam as a steady supply, or to meet rapid peaks. The result of years of development, the Storage Boiler incorporates multiple patented technologies for unparalleled performance.
< 1 s
< 60 s
16 barg
> 95%
94%
> 20 years
It starts with the Heat Cell
The Heat Cell is the heart of the Storage Boiler, where heat is generated, stored, and used to raise steam. The Heat Cell includes a thermal core comprising blocks of Caldera’s proprietary storage material, build up on a cylindrical steel base, and is completed with a vacuum-insulated cover. The thermal core charges from 250°C (‘empty’) to 500°C (‘full’). The Heat Cell can output steam from stored energy, or run as an e-boiler.
Water treatment
Before water enters the Heat Cell, it is treated to the quality required for reliable steam generation. As steam is generated within the Heat Cell’s thermal core, the embedded steam pipework needs clean, controlled water. This avoids minerals and impurities that could cause scale, deposits or corrosion. The Storage Boiler therefore includes ultra-pure water treatment. The exact design depends on the site's existing water supply, condensate return and water treatment arrangements.
Smart controls manage charging and site limits
The Storage Boiler’s controls manage when the system charges, how it operates within site grid connection limits, and how it responds to steam demand. The controls can monitor the site's electrical import so the Storage Boiler does not overload the grid connection. If the site has spare electrical capacity at certain times, the system can charge within that available headroom.
The controls can also connect to optimisation platforms. These can provide signals on when electricity is cheapest, when on-site generation is available, or when the site may be paid to increase or reduce electrical consumption.
TECHNOLOGIES
Storage block: Caldera’s conductive iron-and-aluminium composite, with embedded elements and pipework.
Storage block: Caldera’s conductive iron-and-aluminium composite, with embedded elements and pipework.
Conductive blocks
The Heat Cell’s thermal core is built from iron pellets within a recycled aluminium block. This unique material is dense and durable. The metal’s conductivity spreads heat evenly from the embedded elements and charges faster than alternative materials such as sand, brick, or concrete.
Vacuum insulation
The thermal core of each Heat Cell sits inside a double-walled vacuum vessel. Without gas between the walls, heat cannot escape by conduction or convection; a proprietary inner layer suppresses radiative loss. This patented insulation system means the Heat Cell does not need to be clad on site.
Integrated steam generation
Steam is produced inside the thermal core itself, meaning there is no separate steam generator to buy, house, or maintain. This avoids losses from a second heat-transfer step.
Prefabricated sub-assemblies
Each sub-assembly in the Storage Boiler is designed to be factory-built and tested, ready for road transport. This enables rapid, reliable on-site assembly before commissioning.
Get in touch
Whether you are interested in a site suitability assessment, partnering, or anything else, we look forward to hearing from you.
