How Process Electrification is Revolutionizing Industry and Reducing Emissions

Despite the widespread use of paper straws and electric cars, the global efforts to combat climate change are still falling behind. What is preventing progress? Let’s talk about industrial emissions, a topic that deserves our attention.

These emissions make up a significant portion of the United States’ total, and consist of some of the most challenging greenhouse gasses to reduce. For years, scientists have been exploring how the manufacturing sector, including areas like restaurant furniture production, can contribute to significant reductions in emissions. They have been focusing on developing new technologies and improving energy efficiency.

One of the most exciting developments in the field involves process electrification, which involves the substitution of fossil fuels with electricity as the main energy source for industrial processes. In this article, we will explore the concept of process electrification, its functionality, the advantages it provides, and why it surpasses the benchmarks established by traditional systems.

Understanding Process Electrification

When we talk about process electrification, we are referring to the process of replacing technology that operates on fossil fuels, such as coal, oil, and natural gas, with electrically powered systems. The ultimate objective is to develop systems that are entirely powered by renewable energy sources and to reduce the emissions of greenhouse gases that would otherwise be created by the manufacturing process via the usage of these systems. Process electrification has emerged as a significant trend all over the globe as businesses strive to lessen their impact on the environment and make the most of the opportunities presented by environmental incentives. 

Which Processes Have the Potential to be Electrified?

Manufacturers have the opportunity to harness the power of electricity in various ways, particularly in process heating and machine drive. Process heating is the driving force behind the operation of ovens, furnaces, and boilers in manufacturing processes. Machine drive is the fascinating force that propels various machines, enabling them to perform a wide range of tasks, from smoothly operating conveyor belts to efficiently powering drilling rigs. Electrification has found its way into various applications, including cooling and air conditioning, compressors, pumps, fans, and ventilation systems. In each of these instances, the use of electricity can serve as a viable alternative to combustion-powered systems, resulting in a significant reduction in emissions.

How Can Process Electrification Make Manufacturers Greener?

One major advantage of process electrification is its potential to significantly reduce manufacturers’ carbon emissions. By embracing the power of electricity, factories can significantly decrease their carbon footprint and move towards a more environmentally friendly future. As the world becomes more conscious of its environmental impact, there is a noticeable shift away from fossil fuels towards renewable energy sources. This option not only offers long-term cost savings, but also aligns with national objectives of reducing dependence on fossil fuels.

In addition, adopting process electrification can greatly enhance operational efficiency for manufacturers. Electric motors and machines are commonly known for their compact size, light weight, and low maintenance needs compared to traditional combustion systems. They tend to be more efficient at completing tasks, resulting in lower power consumption. This can result in a reduced carbon footprint and decreased energy expenses overall.

Process electrification is a valuable tool for manufacturers to ensure compliance with the latest climate regulations. Across various regions, especially in Europe, there has been a noticeable rise in stringent regulations concerning emissions from industrial processes. By embracing electric power, manufacturers can avoid expensive penalties and maintain a competitive edge in terms of environmental regulations.

What Makes Process Electrification a Better Choice Than Conventional Systems?

Despite the immense potential, there are still numerous manufacturers who have not embraced process electrification. And in a way, it’s understandable for them to be hesitant. Why bother with embracing a fresh perspective when you can simply stick to the tried and true?  

It’s clear that process electrification provides significant benefits in terms of cost savings, environmental sustainability, and overall performance. In addition to reducing carbon emissions, it also contributes to long-term cost savings. It’s worth noting that this advanced system is not only more reliable and efficient, but it also eliminates the need for costly maintenance and frequent repairs that are often associated with traditional combustion systems.

Embracing process electrification may involve an initial investment, but the long-term advantages greatly surpass the expenses. According to recent data, a significant portion of on-site energy systems can already be electrified, and this percentage is expected to increase even further in the near future. Time is running out and the landscape is changing — manufacturers must make a choice: embrace the future now or risk being left behind.

Does Process Electrification Have Any Use Beyond Environmental Constraints?

Electric machines offer a safer alternative to combustion systems, as they eliminate the need for extensive fuel storage and maintenance. This reduces the potential risks associated with mishandling such systems. By embracing electric power, manufacturers can greatly reduce operational risks and foster a more efficient and employee-friendly work environment.

The fossil fuel industry is constantly changing and unpredictable. It is extremely responsive to changes in the economy, international conflicts, and the preferences of consumers. In addition to these factors, the oil and gas industry is controlled by a small group of producers, allowing them to manipulate prices at will. Process electrification offers a solution that brings about certainty and ensures pricing stability over the long run.

Electric systems have a natural cleanliness and require significantly less maintenance compared to traditional systems. This indicates that manufacturers have the opportunity to reduce costs on costly repairs and maintenance fees by opting for electric machines. This can be particularly advantageous for those who are working with limited budgets.

Typically, electrified processes tend to be more energy efficient compared to those that rely on fossil fuels. Electric motors and machines are incredibly efficient, resulting in substantial long-term energy savings.

As an illustration, the methods used for drying alone account for approximately 10 to 25 percent of energy consumption in industrial settings. By replacing traditional natural gas burner systems with heat pumps, the efficiency of this share could be increased by 80%.

Electric machines and motors have the advantage of generating less heat compared to their fossil fuel counterparts, resulting in reduced wear and tear over time. This results in reduced need for repairs and replacements, leading to significant cost savings over time.