Arthur Moslow, Global Electrification Project Manager at Kanthal, unpacks the details of this transformation, providing valuable insights into the reasons for this shift, the practical steps involved, and the long-lasting benefits for the industrial sector.
Why Electrify Industrial Processes?
The primary reason for electrifying industrial processes is to reduce carbon emissions in industries, especially those with significant emissions such as the steel industry. Moslow points out that the steel industry alone contributes to approximately 10% of global CO2 emissions. The EU's 2030 framework is committed to reducing greenhouse emissions by 4% and promoting the use of 32% renewable energy. Similarly, the United States has pledged to reduce net GHG emissions by 50-52% below 2005 levels by 2030 and achieve net zero emissions by 2050.
Arthur Moslow, Global Electrification Project Manager at Kanthal.The transition to electric processes aligns with these global initiatives, aiming to reduce emissions and increase the share of clean energy.
The steel industry’s high emission footprint makes it a critical target for decarbonization efforts. However, the methods used to reduce emissions can be applied to all industries.
“The steel industry’s high emission footprint makes it a critical target for decarbonization efforts. However, the methods used to reduce emissions can be applied to all industries. To achieve a more energy-efficient system, significant investments in energy production and consumption are necessary.”
“However, it is crucial to ensure that the electricity used during this transition is sourced from clean and renewable energy to avoid simply shifting emissions from one source to another,” Moslow emphasizes.
Processes Ready for Electrification
Moslow identifies specific processes across various industries that are ripe for conversion to electric.
Steel:
- Continuous Annealing Line (CAL)
- Continuous Galvanizing Line (CGL)
- Annealing and Coating Line (ACL)
- Annealing and Pickling Line (APL)
- Roller Hearth Furnace
- Walking Beam Furnace
- Pusher Furnace
Aluminum:
- Melting furnace
- Holding furnace
- Tilting furnace
Heat-Treatment/Automotive:
- Case hardening – carburizing, carbo-nitriding
- Batch and Continuous furnaces (pusher, roller hearth, etc…)
- Annealing & Tempering
- Regenerative Thermal Oxidizer (RTO) – for solvent removal
Glass:
- Glass forehearth
- Batch processing
“The aforementioned industries are characterized by the utilization of large-scale industrial furnaces. Traditionally gas-fired, these furnaces are now prime candidates for conversion to electric, a shift that promises both energy efficiency and environmental benefits,” Moslow explains.
Steps to electrification
The conversion process involves four essential steps:
1. Calculate Electrical Power Requirements: This step involves precise calculations, often aided by CFD modeling, to determine the required electrical power. Moslow emphasizes the importance of ensuring clean energy sources for maximum efficiency.
2. Design Electric Heating System: This phase involves making space for heating elements and designing an electric heating system tailored to the specific process requirements.
3. Remove Old Gas System: Retrofitting the existing system involves removing the gas-fired heating system and making necessary repairs or modifications to the furnace.
4. Install New Electric System: The final step is to install the new electric heating system, ensuring the availability of adequate electrical power.
Key Stakeholders in the Conversion Process
Identifying the key stakeholders is crucial during the electrification process. Moslow points out that beyond the primary customer contact, involving customer management and understanding the corporate green initiatives is vital. Corporate representatives driving green initiatives should be considered alongside site-specific contacts to ensure a smooth transition.
The success of the conversion process relies on effective communication and collaboration among key stakeholders, including the main customer contact, customer management, and those spearheading green initiatives.
“The success of the conversion process relies on effective communication and collaboration among key stakeholders, including the main customer contact, customer management, and those spearheading green initiatives. Understanding the motivations behind the conversion, whether driven by corporate-wide green initiatives or specific site-based goals, is essential for a seamless transition,” Moslow insists.
Why Kanthal is the Preferred Choice
When it comes to customers who are transitioning to electric processes, Kanthal is the preferred choice. Moslow explains why.
“With a broad range of metallic cartridge elements, silicon carbide heating elements, and MoSi2 heating elements, Kanthal offers flexibility and customization to cater to various furnace needs and temperature requirements. This makes Kanthal an ideal partner for a successful transition.”
“The choice of materials for electric heating elements is crucial for a successful conversion. With decades of experience, Kanthal has developed an extensive portfolio of materials that match various industrial processes' temperature requirements and atmospheric conditions,” Moslow adds.
Long-term benefits of the transition
The shift to electric processes yields several long-term benefits:
- Improved Energy Efficiency: Electric systems can achieve nearly 100% thermal efficiency, significantly reducing energy costs compared to gas systems.
- Increased Thermal Efficiency: Electric heaters utilize more heat within the furnace, minimizing losses with exhaust gases.
- Precise Temperature Control: Electric systems offer precise temperature control, enabling improved process optimization.
- Excellent Temperature Uniformity: Electric heating provides consistent and even temperatures across the entire process, enhancing product quality.
- Cleaner, Quieter, and Safer Environment: Electric heaters emit no harmful exhaust gases in the factory, resulting in a cleaner and quieter working environment and enhancing safety.
- Zero CO2 Emissions: If the electric heater is powered by renewable energy, then the process effectively becomes emissions-free, aligning with sustainability goals.
- Minimal Maintenance: The absence of excessive oxidation and combustion byproducts reduces the need for maintenance and cleaning, which is particularly beneficial in industries like steel manufacturing.
To sum up, transitioning to electric-powered industrial processes is a smart way for industries worldwide to address environmental concerns and improve efficiency while also reducing emissions and securing a sustainable future.
