An industry is essentially a category of businesses that produce similar products or services. They can be categorized based on the goods manufactured and the size of an industry. Primary industries extract raw materials from the Earth, like mining, agriculture and fishing; secondary industries use those raw materials to manufacture finished goods, like car manufacturing, furniture making and textile production; and tertiary industries provide services to consumers and businesses, like education, healthcare and retail. Similarly, heavy industries mostly involve large-scale production of heavy goods, like steel and shipbuilding and light industries deal with smaller consumer goods, like clothing and electronics.

What are the energy needs of an industry?

Industries are major consumers of energy, accounting for a significant portion of global energy use. This is because many industrial processes are energy-intensive, requiring large amounts of power for machinery, heating, cooling and other activities. The energy needs of an industry depend upon the type of load being used.

1. Electrical energy: This is the most common type of load in most industries. It's used to power a wide range of equipment, from motors and lighting to computers and control systems. Industries can further be categorized based on their electrical load:

• High-power users: Industries with machinery requiring significant electricity, like steel mills, paper production or aluminum smelting.
• Moderate users: Industries with a mix of power needs, like car manufacturing or chemical processing.
• Low-power users: Industries that primarily use lighting, electronics and other equipment with minimal power requirements.

2. Thermal energy: This type of load is crucial for processes involving heating or cooling. Industries with significant thermal energy needs include:

• High-heat processes: Metalworking, glass production and certain chemical reactions require intense heat, often achieved through burning natural gas or using electric furnaces.
• Moderate-heat processes: Food processing, textile manufacturing and some plastic molding require controlled heating at various stages.
• Low-heat processes: Certain industries may need low-level heating for specific applications, like maintaining specific temperatures in warehouses or drying products.

3. Fossil fuels: While some industries use these directly to generate electricity on-site (cogeneration), others utilize them as a fuel source for heating or specific processes:

• Natural gas: A versatile fuel used for heating, powering boilers and even as a raw material in some industries.
• Coal: Primarily used in power generation for electricity within the industry or fed back to the grid.
• Petroleum liquids: Used in specific processes or for transportation within large industrial facilities.

4. Hydraulic power: This uses pressurized liquids, typically water or oil, to transfer power and operate machinery. It's commonly seen in industries like construction (operating excavators or lifts) or manufacturing (metal forming or forging presses).

5. Compressed air: It is used for powering pneumatic tools and machinery in various industries.

6. Process steam: This is high-pressure steam used for various industrial processes beyond simple heating. It is often a key component in sterilization (pharmaceutical industry), distillation (chemical refineries) or driving turbines for electricity generation within a facility.

7. Renewable energy: Some industries are increasingly adopting solar power, biomass or geothermal energy to meet part of their energy needs.

How can industries manage their energy demand?

Industrial energy use differs from residential or commercial use because industries often have periods of peak demand when they require a lot of power at once. The industrial sector can adopt different methods to reduce its energy bills, improve energy efficiency and reduce its reliance on fossil fuels. The following are the popular methods that can be used:

Demand-side management (DSM):

This is a crucial approach where industries focus on reducing or shifting their electricity demand to improve grid stability and potentially lower costs. DSM basically helps by:

• Load shifting: DSM programs incentivize industries to move energy-intensive tasks to off-peak hours when electricity demand is lower. This reduces the strain on the grid during peak periods.
• Load shedding: As a last resort, industries can participate in programs that allow them to temporarily reduce their power consumption during peak demand periods in exchange for compensation.
• Energy efficiency upgrades: DSM programs often provide rebates or incentives for industries to invest in energy-efficient equipment and processes. This lowers their overall power demand.

On-site power generation and storage:

• Combined heat and power (CHP): This technology generates electricity and captures waste heat for other uses within the facility, reducing reliance on the grid for both power and heating.
• Renewable energy: Industries can install solar panels, wind turbines or other renewable energy sources to generate some of their own electricity, reducing dependence on the grid during peak hours.
• Battery storage: Excess electricity generated on-site or during off-peak periods can be stored in batteries and used to meet peak demand needs, reducing reliance on the grid.

Smart grid Integration:

• Real-time pricing: By integrating with smart grid technologies, industries can access real-time electricity prices and adjust their consumption accordingly. This allows them to take advantage of lower prices during off-peak hours.
• Demand response programs: These programs allow industries to automatically reduce their electricity consumption in response to real-time grid conditions, helping to stabilize the power supply.

Conclusion

A large percentage of the world's total energy consumption is attributed to industrial processes. The reason behind this is that a lot of machinery, heating and cooling needs a lot of power, making many industrial operations energy-intensive. Industries can negotiate contracts with utilities that offer time-of-use pricing or other incentives for reducing peak demand. Working with utilities on grid modernization projects can benefit both parties by improving grid efficiency and reliability, ultimately leading to a more stable power supply.