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Decarbonization and cost reduction in industrial heating systems with electric hot oil heaters
The adoption of electric thermal oil heaters has seen a significant rise in recent years, aligning with the global trend towards electrification and decarbonization across various industrial processes. Installing an electric hot oil boiler enables industries to transition from traditional heating methods that rely on thermal fluid systems, making it easier to reduce carbon emissions.
There are two main reasons driving this shift: economic benefits and environmental impact:
1. Electric boilers typically have lower operational costs due to reduced maintenance needs and no requirement for handling or storing hazardous fuels. Additionally, when electricity prices are lower than natural gas, these savings become even more pronounced.
2. Replacing combustion-based thermal fluid heaters with electric ones contributes to reducing carbon emissions. Boilers fueled by fossil fuels like oil or natural gas release carbon dioxide and other pollutants. By switching to electric alternatives, companies can avoid direct emissions during the heating process.
However, the effectiveness of this transition in terms of decarbonization depends heavily on the source of the electricity used. If the power comes from renewable energy sources, the environmental benefits are substantial. Conversely, if the electricity is still largely generated from fossil fuels, the emission reductions will be less significant.
In some cases, combustion heaters are kept as backups or used during peak production periods, especially when energy cost analysis suggests it's more economical.
Switching to electric hot oil boilers offers several additional advantages beyond cost and environmental savings:
- Electric heaters are more efficient, requiring less energy to produce the same level of heat, which reduces both energy use and emissions.
- They emit fewer pollutants, including nitrogen oxides, particulates, and volatile organic compounds, which are common in combustion boilers.
- Electric systems take up less space and offer greater flexibility in installation since they don’t require fuel storage infrastructure.
- These boilers often provide better control and automation, allowing for precise temperature adjustments and improved efficiency.
- Adopting electric boilers can help companies meet environmental regulations and avoid potential fines or penalties.
Before replacing a combustion thermal fluid boiler with an electric one, it’s important to consider several factors to ensure the new system meets performance expectations:
- The new heater must efficiently and reliably meet the required heat demand and capacity.
- It should match or exceed the energy-to-heat conversion performance of the current system.
- Investment and operational costs should be analyzed, including electricity rates and maintenance expenses.
- The availability and source of different energy options should be evaluated, particularly if the goal is to reduce carbon emissions.
- The existing electrical infrastructure must be able to handle the added load without major upgrades.
- Compliance with local regulations, permits, and safety standards is essential.
- Integration with existing heating systems and how the change affects production capacity must be considered.
- A life cycle analysis of both options, from manufacturing to decommissioning, helps assess long-term environmental impact.
Deciding to replace a combustion boiler with an electric one requires a thorough evaluation of these factors to determine what best suits the company’s operational, financial, and environmental goals. Consulting with experienced engineers and consultants in energy and industrial processes is crucial for accurate assessment and guidance.
Hybrid systems, where both combustion and electric boilers operate simultaneously, offer a balanced approach. These systems combine the benefits of both technologies, enhancing efficiency, flexibility, and reliability. Before implementing such a system, detailed engineering analysis is needed to evaluate compatibility, energy costs, and overall system performance. Proper design ensures optimal operation and supports the facility’s decarbonization goals.
Several reasons support the use of hybrid systems:
- They allow for cost optimization by using the most economical energy source at any given time, whether gas or electricity.
- Combining both types of boilers can help manage varying heat demands, with combustion boilers handling peak loads and electric ones adjusting quickly to fluctuations.
- Hybrid systems provide operational flexibility, enabling simultaneous operation during high-demand periods.
- They improve system reliability by offering backup in case of equipment failure.
- Effective control and automation systems are necessary to manage the coordination between both boiler types.
Pirobloc’s R&D team is developing a smart hybrid system capable of accessing real-time gas and electricity price data to decide which boiler to activate based on cost-effectiveness. This intelligent system offers benefits such as cost savings, improved energy efficiency, greater flexibility, and reduced emissions, especially when powered by clean energy sources.
Case Study 1: Replacing a Thermal Oil Boiler with Two Electric Boilers
A client sought to replace two 1.5 million kcal/h fuel oil thermal oil boilers with two electric ones. The study aimed to determine the appropriate power and ensure continuous operation to maintain stable temperatures for asphalt tar. The transition was driven by the client’s commitment to reducing emissions. One existing boiler would remain as a backup but switched to diesel for lower pollution.
Case Study 2: Hybrid Installation with a Thermal Oil Heater and an Electric Heater
This study evaluated the feasibility of installing an electric thermal fluid boiler alongside an existing natural gas-fired boiler. The goal was to switch between the two based on fuel prices, optimizing costs and efficiency. Pirobloc proposed a solution with matching heating capacity, updated pumps, and revised expansion tanks to support the hybrid system.
Carles Ferrer, an Industrial Engineer from the University of Barcelona and Sales Director at Pirobloc, has extensive experience in thermal fluid projects across over 80 countries. His expertise in industrial heating solutions continues to drive innovation and sustainability in the sector.