Electrification of industrial process heating

Electrification of process heating is about more than replacing gas or oil with an electric heating element. Power demand, temperature, operating hours, energy consumption, electrical capacity and control must align, and the financials must be assessed before the investment is decided.

At Newtronic, we advise on how electric heating can be integrated into the existing or future process. We assess the technical options, calculate power and energy requirements, and compare electric heating with the current energy source. This provides a concrete basis for evaluating both full electrification and hybrid solutions.

The goal is not necessarily to electrify as much as possible. It is to find the solution that best fits the process, operations and financials.

Electrification starts with the existing process

The first task is to understand how heat is produced and used today.

How much energy does the process use? What temperature is required? How many hours does the plant run? Is the heat demand constant or variable? And how much electrical power will be required if the current energy source is to be replaced?

These are the kinds of questions that determine whether electrification is technically realistic and which solution is relevant.

For some processes, existing gas or oil heating can be replaced directly with electric process heating. Elsewhere, it makes more sense to electrify part of the process or establish a hybrid solution where multiple energy sources can be used.

That is why we look at the process before the product.

What does it cost to electrify industrial process heating?

A technically feasible solution is not necessarily a good investment. Therefore, electrification should be assessed based on both CAPEX and the expected operating costs.

On that basis, different scenarios can be compared—for example, continued operation with the existing energy source, full electrification, or a hybrid solution.

The business case must provide a realistic picture of the investment and show which parameters have the greatest impact on the financials.

Power demand is just as important as energy consumption

Two processes can use the same amount of energy over a year and still place very different demands on an electrical solution.

A process with a high heat demand for a few hours requires high electrical power. Another process may have a lower, continuous heat demand. This affects the heating equipment, the electrical installation and how the plant should be controlled.

That is why we do not look only at kWh.

We also look at the load profile and when the power actually needs to be available. This provides a better basis for assessing sizing, electrical capacity and the possibilities for controlling energy consumption more flexibly.

Use electricity when it makes the most sense

Electric process heating makes it possible to closely link heat production with control and energy data.

If the process allows flexible operation, heat production can, for example, be adapted to electricity prices, production schedules, temperature setpoints and the maximum power the company wants to draw from the grid.

At Newtronic, we do not only advise on this option. We can also supply the necessary automation and control so that energy consumption is regulated according to the chosen strategy.

This may be relevant for, among other things, electric boilers, tanks and other processes where heat can be produced or stored at times that are more financially attractive.

However, spot price optimisation is not relevant for all processes. Process requirements and production come first, and flexibility is therefore assessed on a case-by-case basis.

Electrification does not have to be all or nothing

It is not always necessary or financially optimal to replace the entire existing heat supply at once.

A hybrid solution may be relevant if the company wants to retain the existing energy source while also establishing electrical capacity.

This can make it possible to choose the energy source based on, among other things, process demand, energy price and available capacity.

Subsidies can be part of the business case

In relevant projects, energy efficiency improvements and electrification may be covered by support schemes such as the Erhvervspuljen.

At Newtronic, we help investigate the options and can assist with both the application and the technical calculation and documentation basis.

Subsidies should be considered early in the project. That is why we look at the options already when the business case and solution principles are being assessed.

From idea to a concrete electrification project

An electrification project typically begins with existing process data and ends with a decision basis for the subsequent engineering.

We start by understanding the current energy supply and heating process. We then calculate the heat and power requirements and assess relevant electrical solution principles.

Have the electrification potential assessed

Are you considering replacing or supplementing gas, oil or another energy source with electric process heating?

Please send us information about your current energy source, energy consumption, process, temperatures, operating hours and known power requirements.

We will then take your actual process as the starting point and assess the options for electrification.