Alternatives to direct fuel combustion are available in the form of electrified heating. Source: Shutterstock/Travelpixs

Today a massive effort is underway to eliminate industrial CO₂ emissions caused by the combustion of fossil fuels. Reaching “net zero” is a daunting task, as companies have relied upon fossil fuel-based heating and steam generation since the dawn of industrialization.

The good news is that viable alternatives to direct fuel combustion are now available in the form of low and medium-voltage electrified heating. Chromalox’s Decarbonization Assessment Program is designed to introduce facilities engineers, managers and technicians to this new technology and recommend specific site solutions.

The technology

The combustion of fossil fuels — for all of its faults — is a fantastically dense source of energy. A powerful central combustion system is therefore very difficult to replace with typical low voltage (LV) heating systems in the 380 V to 1,000 V range, given this technology’s power limits and current demands. Chromalox’s DirectConnect medium voltage (MV) heating systems, however, can operate at up to 7,200 V, requiring a fraction of the current of their LV counterparts, and therefore much less physical wiring and conductor hardware. Robust insulation is needed for safe operation at these voltages, which Chromalox accounts for in their designs and tests thoroughly.

While DirectConnect MV facilitates new energy transfer possibilities, LV heating still has its place. LV is typically not the optimal solution to replace or retrofit existing central heating infrastructure, but it can be effectively used for distributed heating, where thermal energy is applied closer to its point-of-use. Distributed heating results in less thermal loss during transport and reduces the need for insulation and other auxiliary components which are required to support more complex heating networks. This should be considered when attempting to make optimal use of existing infrastructure or when designing a facility from scratch.

A tailored solution

Chromalox’s Decarbonization Assessment Program starts with a site assessment, where a Chromalox Certified Decarbonization Specialist will walk the facility in order to identify electrification opportunities. The Program focuses on three categories of improvement, which may be implemented individually, as a whole or in stages depending on facility needs:

Decentralize

Chromalox will first look toward reducing the central heating burden, placing heat generation directly where needed. This can take the form of point-of-use steam generators, tank heaters, process air heaters and other devices as appropriate. This step can reduce central fuel-fired heating needs, while increasing efficiency by mitigating transfer losses and improving process control and stability.

Optimize

In conjunction with parent company Spirax Sarco’s First for Steam Solutions, Chromalox can optimize steam systems to reduce inefficiencies from poor system design and antiquated components. Further opportunities may involve the use of steam superheaters, booster heaters and heat trace cable in order to boost process quality, mitigate excessive heat losses and elevate overall system performance.

Final decarbonization

Once a system has been appropriately decentralized and optimized, Chromalox can tackle the remaining central heating needs via their DirectConnect MV technology. This may mean replacing heating equipment entirely or providing Chromalox retrofit kits that can convert gas fired equipment to use electricity. These options mean that disruptions, cost and environmental concerns are minimized, while still producing optimal results.

With the assessment, a specific site plan is generated, and facility personnel will receive a sustainability and impact report for review. This will outline the proposed solutions and costs, along with CO₂ reduction metrics that outline their short- and long-term impacts. The transition from fossil fuels to electric technology is further supported by Chromalox’s team of field service experts via installation checks, startup and commissioning services, and onsite personnel training through ongoing equipment maintenance programs.

Chromalox

Chromalox, with over 100 years of history of electrical heating innovation and its global reach, is uniquely suited to help with today’s industrial electrification challenges. Find out more about their unique offerings or get in touch today to have a Chromalox Decarbonization Specialist perform an on-site assessment by visiting the Chromalox website.