As the world begins to explore new ways to reduce CO2 emissions, the power sector is becoming more and more skilled. In particular, it is gaining momentum in the field of transportation and heating solutions, and is expected to further increase its share of the global energy mix in the future. In order to solve the problem of low energy efficiency and high carbon emissions of traditional gas-fired heating, Alleima, a global leader in the advanced stainless steel and special alloy industry, together with its sustainable heating technology expert Kanthal Company, brought us a new industrial electric heating solution. This solution can be used in a variety of industrial processes and has the potential to significantly reduce carbon emissions. By replacing traditional gas-fired heating processes with electric solutions, manufacturers will reap significant benefits in terms of improved energy efficiency and product quality, while creating a safer, cleaner, and sustainable working environment.
Electric heating, thermal efficiency of more than 90% clean energy
Since electric heating does not involve combustion, it is possible to eliminate CO2 emissions from the heat treatment process as long as electricity from fossil fuels** is not used, and NOx and SOx emissions remain zero regardless of how electricity is used. In addition, due to the directness of electric (resistance) heating, the thermal efficiency of electric heating is as high as more than 90%, and almost all energy inputs can be converted into heat, while the average efficiency of gas heating is only 50%.
According to Alleima, electric heating enables more precise temperature control, reduces the need for continuous monitoring of the heating process, and enables more uniform heating results. In terms of maintenance, electric heating systems are significantly less demanding to maintain than systems with hundreds of burners, which often require routine maintenance.
With so many indisputable advantages, electrification seems like a natural trend. This begs the question, why hasn't it been rolled out on a larger scale?
Get out of the misunderstanding of electric heating
Dilip Chandrasekaran, Business Development Director at Kanthal, an Alleima company, a global expert in sustainable heating technology, says the main obstacle to electrification is related to a series of widespread misconceptions.
"There is still a common perception that electric heating cannot provide the power output and temperature required for many industrial processes," Chandrasekaran notes. And it turns out that Kanthal's electric heating solution has no problems in this regard. He adds: "Today, many processes in steel manufacturing can already be electrified, while others can be electrified with just a few additional development efforts. We are ready to work with more manufacturers to help them develop customized solutions to meet their needs. ”
Rickard Dahlgren, Vice President and President of Kanthal's Heating Systems Business Unit**, also said Kanthal is not only able to provide customers with electric heating solutions of up to 1,850 meters, but also achieves higher energy intensity than gas heating and can be scaled to large industrial operations. "Combined with fossil-free electricity, electric heating is a key enabler of the transition to a fossil-free future," he stressed. ”
The electrification process has already begun
McKinsey, a global management consulting firm, agrees with this view. Its most recent report, "Unleashing the Opportunity of Industrial Electrification," states that "electrification is advancing and demand is surging across the value chain."
The report shows that as the industry's demand for critical assets continues to increase, such as wind and solar systems to provide green electricity, heat pumps to decarbonize building spaces and water heating, battery energy storage systems to address intermittent grids, electrolyzers to produce green hydrogen, and EV charging infrastructure to support the transformation of the mobility industry, companies across the value chain should act quickly to adapt to this trend. The McKinsey report further clarifies that companies that act now and support their plans by investing wisely will be industry leaders.
Growing demand for electricity
According to McKinsey's Global Energy Outlook 2022**, global electricity consumption will grow significantly in the coming years as electricity use continues to increase. Without taking into account more aggressive carbon reduction targets, current trends would see future electricity demand more than triple, from around 83 million terajoules (TJ) in 2020 to more than 2 in 20505.2 billion terajoules (TJ).
Rickard Dahlgren, Vice President and President of Kanthal's Heating Systems Business Unit, believes that the current boom in power solutions is driven by a combination of environmental and climate concerns and growing political pressure. "As politicians and regulators increase their desire to incentivize renewable electricity production, there will be increasing opportunities for the industry to transition to electricity, especially to green electricity," he noted. Players in key industries have begun to position themselves to take advantage of this opportunity. ”
Kanthal solutions for high-temperature heating.
Dahlgren further explains: "As an expert in the field of electric heating, Kanthal is ready to support this transformation in any industrial process that requires high-temperature heating. When we started talking about furnaces that operate at very high temperatures, our expertise is truly at the forefront of the market. ”
With more than 90 years of expertise in the field of industrial electric heating, and the products and industry advantages of its parent company, Alleima, a global leader in advanced stainless steel and specialty alloys, Kanthal can provide industrial customers with a range of professional services for the transition from fossil fuel furnaces to electric furnaces. At the same time, Kanthal offers a wide range of products and solutions for sustainable industrial electric heating, and leverages its advanced technology, market-leading knowledge and global reach to effectively support industry customers on their journey to electrification.
Kanthal's product range includes a wide range of advanced materials for electric heating and heat-resistant applications, primarily for customers in the industrial heating and appliance sectors. The product range also includes ceramic and metal resistance furnace elements, as well as radiation modules and tubes for heating systems, which often require a higher degree of processing and refining before being delivered to the customer.
Based on traditional fields, we are committed to emerging industries
In addition, Kanthal is focused on fast-growing emerging sub-sectors such as semiconductors, solar energy, and lithium-ion batteries, demonstrating that they are ready to support the electrification transformation of these key industries. At the same time, the company also has rich experience in electric heating solutions in traditional industries such as iron and steel, metallurgy, etc.
For example, the current challenge in the steel industry is the need to expand the size of furnaces. Kanthal works closely with leading research institutes and industry partners to provide the market with high-quality power solutions that support furnace sizing innovations.
Another challenge facing the steel industry is how to decarbonize the emissions-intensive ironmaking process. One way to do this is to replace coal with hydrogen, but this requires super-large-scale preheating of hydrogen. With deep industry experience and R&D capabilities, Kanthal said that he has the strength and technical reserves to develop corresponding solutions to achieve this green transition.
Dahlgren, Global Expert in Sustainable Heating Technology, Vice President and President of the Heating Systems Business Unit, concludes: "As a socially responsible company, we are driven by a commitment to sustainability. We will actively promote the integration of sustainable and climate-oriented solutions into our operations and customer service. We firmly believe that advanced electrothermal development technologies will help industrial partners reduce emissions and ultimately benefit humanity. ”