Electrification of heat
This post is the first in a series where we explore technical solutions to decarbonise the chemical industry. I have decided to start with one of the technological innovations that predictions set to be commercially available only by mid-century. While on the other hand, the electrification of heat has the biggest potential to reduce significantly process emissions.
It is also one of the so-called Power-to-X routes (which we will explore in future publications) to utilize and store renewable electricity. Power-to-heat solutions have the potential to supply low-cost and carbon-free heat for residential, commercial and industrial applications. Renewable energy supply solutions, in combination with electrification, account for 40% of total emissions reductions.
What are the key challenges and opportunities?
Industrial demand is very specific, and the high temperature requirements limit the application of heat pumps (which can provide up to 160C only). Within the chemical industry, the most energy-intensive conversion processes are cracking and the production of base chemicals, such us methanol, ammonia and hydrogen, used in downstream processes to build more complex molecules.
In 2017, 16% of the total estimated fuel consumption for energy was used in the petrochemical industry to provide high temperature heat (400-1000C) in steam reforming.
There are already advanced technologies that could be translated, such technologies are the following ones:
• Radiant (IR, UV) heats the surface of an object.
• Induction heating uses electromagnetic waves to create eddies which enables a uniform heating of an object.
• Dielectric (microwave, radiofrequency) systems can create a high to very high heat input.
Typically, these technologies are used in specific application. For application in the energy-intensive industries, the technology needs to be developed. Compared to conventional technologies these technologies are characterized by the trio: High investment cost + Need for R&D to bring the technology to maturity + Process improvement potential.
In terms of technology availability, the roadmap for high temperature heat electrification does not set specific enough milestones. In the next 2 years, it will still be in research phase. The first applications development should occur between 2023 and 2030, with the implementation of the first large scale project. Beyond 2030 key processes, like cracking, should be electrified at a commercial level. The degree of confidence in these affirmations is medium-low.
So, what is going on concerning R&D?
In terms of energy efficiency developments, technologies are focusing on enhancing heat transfer in the radiation section, using green energy and reducing coke formation. Heat transfer can be increased by implementing three-dimensional (3D) coil technologies such as swirled and dimpled tubes.
We can highlight the project IMPROOF, funded by the Horizon 2020 Framework Program. It tested the energy efficiency improvement of the radiation section of a steam cracking furnace by at least 20 %, while reducing emissions of greenhouse gases and NOx by at least 25%.
The methodology followed by IMPROOF is getting substantial attention because of its ability to be used for electrification of steam cracking. If green electricity can be used, CO2 emissions could be reduced by 30 % and a more impressive emissions reduction of 90 % could be achieved if the concentrated CO2 is captured.
The exciting next step is to develop the process to realize an electrically heated steam cracker furnace. Electric cracking is a giant leap towards a climate neutrality, and here is where the synergies are happening. Collaboration started in 2019 with six major petrochemical producers forming the Cracker of the Future consortium. After that, companies like BASF, SABIC and Linde have joined expertise’s in order to look for solutions and demonstrate this technology at scale. By using electricity from renewable sources, the fundamentally new technology has the potential to reduce CO2 emissions by as much as 90%. Development timeline is in line with the electrification roadmap expectations, 2023 is the targeted year for start-up. In addition, before them, Dow and Shell joined forces, being backed up by different Dutch funding schemes. Their multi-megawatt pilot plant, with potential start up in 2025 is also subject to investment support. The race is on, and the result can only benefit all in the end, decarbonising very energy intensive processes in industry. Nonetheless, the first stumbling blocks are right ahead on the road, the projects presented to the first call for large-scale projects at the EU Innovation Fund platform have not made it into the list of proposals pre-selected for a grant, nor have they been proposed for project development assistance. It seems it is going to be a bumpy ride…
