Productivity improvements through electro-technology application in industrial process heating

Panel: 4. Undertaking high impact actions: The role of technology and systems optimisation

This is a peer-reviewed paper.

Authors:
Baskar Vairamohan, Electric Power Research Institute, USA
Bill Howe, Electric Power Research Institute (EPRI), USA
Joel Watts, Alabama Power
Scott Bishop, Alabama Power, USA
Ammi Amarnath, Electric Power Research Institute (EPRI), USA

Abstract

In U.S. manufacturing, process heating accounts for over one-fifth of total energy use, making it the largest end use of energy. At 12% of all industrial net electricity consumption, process heating is also significant. Process heating therefore presents opportunities for improvements that can significantly benefit industrial customers through cost reduction and improved productivity, while reducing greenhouse gases.

This technical paper uses real world examples to discuss applications of electrotechnology in industrial process heating and to highlight some of the emerging technologies in this field. These emerging technologies, when implemented in a plant, will provide significant energy savings as well as increase productivity.

Two case studies of successful implementation of electrotechnology based process heating, specifically in the area of Infrared heating, will be discussed in this paper. The case studies show how two companies with two different product lines have benefitted by the application of electric Infrared heating technology. Key performance metrics such as payback period of the installation, gains in productivity, reduction in maintenance, improvement in the work space condition, decreasing energy intensity, increased morality of the workers will be quantified (where possible) and described in detail.

This research paper also shares insight into how collaboration between electric utility and the industry has helped in increased production as well as bottom line of the companies under consideration. This kind of utility-industry partnership offers a win-win situation for both the entities involved. The case studies discussed in this paper provides technology transfer opportunity to reach out to other industrial customers who could also benefit from the use of new and efficient process heating technologies.