The transition towards decarbonisation in industrial processes requires the adoption of sustainable practices and efficient technologies, particularly for heating applications. Steam and hot water play an important role in various industrial heating processes, including distillation, Clean-In-Place (CIP) procedures, and space heating, among others. Each industrial site has its unique challenges and opportunities, requiring a thorough review of existing processes, infrastructure, layout, and location. Such an approach ensures that the solutions implemented are not only technically feasible but also economically viable, thereby maximising the benefits of decarbonization efforts. While technologies like Thermal Vapor Recompression (TVR) and Mechanical Vapor Recompression (MVR) have led to improvements in optimising steam consumption, electric boilers and high-temperature heat pumps also offer significant opportunities for industrial sites.
Electric boilers provide an alternative to conventional fossil fuel-based heating systems, offering a cleaner option for steam generation. This transition is particularly impactful when the electricity utilised is sourced from renewable energy, such as wind, solar, or hydroelectric power. However, switching to electric boilers comes with its challenges. The primary hurdle is the need for substantial upgrades to the existing electrical infrastructure to accommodate the increased demand.
On the other hand, heat pumps utilise ambient or waste heat to produce high-temperature water suitable for industrial processes. The underlying principle of heat pumps involves transferring heat from a source, such as the environment or waste heat streams, to a sink, i.e., the process that requires heat. Heat pump technology is highly efficient, with Coefficients of Performance (COP) typically ranging between 2 and 4. This implies that for every unit of electricity consumed by the heat pump, it can produce two to four units of heat energy, significantly reducing the net energy consumption. However, while options for high-temperature water industrial heat pumps continue to evolve and have been applied to many commercial heating applications, steam-generating heat pumps are still in the early stages of development or applications.
Therefore, exploring the possible integration of high-temperature water heat pumps with a proven track record and electric boilers can be beneficial. Heat pumps can be used to elevate low-grade heat to higher temperatures, thereby reducing the overall demand for steam. Subsequently, electric boilers can efficiently meet the reduced steam demand. This approach not only lowers carbon emissions but also enhances the overall energy efficiency of the system.
Our team at Integro Design Engineering Associates (IDEA) Ltd. is currently engaged in exciting electrification projects. Get in touch if you are interested in exploring the potential of your site. We will be happy to review what possibilities exist to tailor a decarbonisation strategy that aligns with your operational needs and sustainability goals.x
