Jan-2025

Powering the future: The role of Electrification

As industries worldwide confront ambitious climate goals, electrification has become a vital strategy for reducing emissions and advancing sustainability.

Miranda Pizzella
Watlow

Article Summary

Whether in manufacturing, energy production, or heavy industries, electrification is transforming industrial processes by driving both environmental and economic benefits. While the primary goal is to move away from fossil fuelbased systems to significantly lower greenhouse gas emissions, electrification offers a broader spectrum of advantages, including improved process control, operational efficiency, and the seamless integration of smart technologies for future sustainability.

Market drivers for electrification
Electrification is no longer a mere trend, it is an imperative for industries under increasing pressure from regulators, consumers, and shareholders to decarbonise. Global agreements like the 2015 Paris Agreement, combined with regional commitments to reduce carbon emissions, are pushing industries to rethink their reliance on traditional energy sources.

Regulatory frameworks, particularly in Europe, which have historically invested in renewable energy, are accelerating the shift toward electric systems. Carbon taxes, incentives for renewable energy adoption, and increased scrutiny on industrial emissions further position electrification as a viable, sustainable solution for industries seeking to reduce their environmental impact and comply with evolving policies. This push is not confined to Europe; North America and Asia are also seeing growing interest in electric process heating driven by a mix of regulatory, market, and cost-saving opportunities. Key industries where electrification is already taking hold include:
• Petrochemical processes (e.g., hot oil systems and reactor charge heaters).
• Renewable Fuels (thermal processes).
• Food and Beverage (drying, frying and baking processes).
• Wood, Paper, and Pulp (drying processes).
• Green Steel (production using electric heating).

However, beyond meeting regulatory demands, electrification can offer compelling financial incentives. While transitioning from gas-fired to electric systems requires an initial capital investment, the long-term savings often surpass these upfront costs. Electric heaters are generally more efficient than their gas-fired counterparts, offering tighter temperature control, faster response times, and significantly lower maintenance costs.

However, beyond meeting regulatory demands, electrification can offer compelling financial incentives. While transitioning from gas-fired to electric systems requires an initial capital investment, the long-term savings often surpass these upfront costs. Electric heaters are generally more efficient than their gas-fired counterparts, offering tighter temperature control, faster response times, and significantly lower maintenance costs.

Traditional gas-fired systems often suffer from issues like coking, fouling, and hotspots, which lead to frequent maintenance and downtime. Unlike gas-fired systems, electric heaters can be integrated with modern controls, enabling real-time monitoring of energy consumption and system performance. This integration leads to planned maintenance intervals while decreasing downtime, optimised energy use, lower operating costs, and enhanced reliability.

The predictability of electricity prices, especially in regions relying on renewable energy, offers a more stable cost structure compared to the volatility of fossil fuel prices. As industries shift towards electrification, they can capitalise on falling renewable energy costs, positioning themselves to benefit from future energy trends such as wind and solar integration.

Integrating the thermal loop: A holistic approach
One of the most transformative aspects of electrification is the opportunity to adopt an integrated thermal loop approach, where heating, sensing, power management, and data analytics work as a cohesive system. This integration not only improves operational efficiency but also ensures that the benefits of electrification are maximised. In contrast to viewing electric heaters as standalone units, industries can utilise a complete thermal solution that allows for greater process control and long-term sustainability.

At the heart of this integration are advanced power control systems that provide real-time feedback and adjust power output based on precise temperature data. These systems, equipped with proportional-integralderivative (PID) controllers, ensure energy is used efficiently while maintaining tight control over process parameters.

A key advantage of an integrated thermal loop is the potential for predictive maintenance. By continuously monitoring system performance, operators can detect system signals earlier in the performance of their application—like temperature drifts or initial signs of heater wear, before they escalate into significant failures. This proactive approach to maintenance not only reduces unplanned downtime but also extends the lifespan of the equipment, ultimately lowering maintenance costs.

Enhancing sustainability through electrification
The most immediate environmental benefit of electrification is the elimination of direct emissions from industrial heating processes. Traditional gas-fired systems contribute directly to CO₂ emissions, whereas electric systems produce zero direct emissions, making a substantial difference in sectors with heavy carbon outputs such as oil and gas, petrochemicals, and manufacturing.

However, electrification’s sustainability benefits go beyond reducing scope 1 emissions (direct emissions from controlled sources). When powered by renewable energy, electric systems also contribute to the reduction of scope 2 emissions (indirect emissions from purchased electricity). This creates a pathway towards carbon-neutral operations, provided the electricity used is sourced from more sustainable energy such as nuclear, wind, solar, or hydroelectric power.

The flexibility of electric systems aligns well with broader sustainability goals. Electric systems can more easily integrate with smart grids and renewable energy sources, allowing industries to adapt to cleaner energy as it becomes available. This adaptability is critical for industries looking to futureproof their operations while meeting ever-tightening environmental regulations.

Overcoming challenges to electrification
While the benefits of electrification are clear, several challenges must be addressed. One of the most significant obstacles is the need for infrastructure upgrades, particularly in facilities originally designed for gas-fired systems. However, medium voltage technology eliminates the need for additional cabling and step-down transformers typically required with lower voltage systems, reducing installation costs and making this an increasing popular and attractive option.

Additionally, some industrial processes require extremely high temperatures, which gas-fired systems are particularly efficient at delivering. While electric heating technology has made significant advances, particularly in areas like high-efficiency heat exchangers and medium-voltage heaters, some high-temperature applications may still favor gas-fired systems. However, innovations continue to expand the range of processes that can be successfully electrified, enabling industries to adopt electric solutions for an ever-broader set of applications.