Chemical Engineering April 2023 - 28

Cover Story
Part 1
Electrification of
Industrial Facilities
Manufacturing complexes may benefit from using more electricity instead of steam
and fuel gas for their energy needs. Improved energy efficiency, lower emissions,
higher reliability and debottlenecking of utility systems may be achieved
James Turner,
Ma Katrina
Sanaie and
Mohamad
Fakhreddine
Fluor Enterprises
E
IN BRIEF
WHERE TO BEGIN
ELECTRIFICATION
OPTIONS
HEAT PUMPS
ELECTRIC HEATERS
ELECTRIC MOTORS
ELECTRIFICATION
SYSTEM IMPACTS
ELECTRICAL
INFRASTRUCTURE
STEAM SYSTEMS
WATER SYSTEMS
FUEL-GAS SYSTEMS
FLARE SYSTEMS
ELECTRIFICATION
CONSIDERATIONS
lectrification is a popular buzzword
when energy transition is
discussed. It can have many different
meanings, and depending
on the subject, it can refer to the private
and business transportation fleet (cars
and trucks), public transportation (buses
and trains) or manufacturing and industrial
processes and facilities.
In process facilities, replacing steam
and fuel gas with electricity can provide
many benefits, from improvements in reliability
to avoidance of boiler-upgrade projects
to lower overall emissions. In short,
if the carbon footprint from the electricity
production is lower than the carbon
footprint from producing the energy
that is replaced by electricity, then there
will be a decarbonization benefit from
the electrification.
This article discusses how electrification
can impact a process-focused industrial
complex, such as a chemical plant or petroleum
refinery, and it specifically focuses
on applying electrification to existing
industrial facilities.
WHERE TO BEGIN
There are several questions or issues
owners or managers of existing industrial
facilities may have when considering electrification
of their facilities (Figure 1).
Is
the facility
operating
at
energy efficiency? Many operators see a
noticeable improvement in
their energy intensity index
(EII) from electrification
of existing steam-turbine
drivers. The calculations
are based on efficient
grid-electricity production,
such as from renewable
sources, compared
to less-efficient boiler
steam production.
Improvements in energy
Air pollution/
emissions?
Fuel?
(oil/gas)
Water?
Steam
production?
Heat users
Power users
FIGURE 1. There are many questions or issues that owners or managers of existing
industrial facilities may have when considering electrification of their facilities
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APRIL 2023
intensity are often a part of a facility's strategic
plans and goals, which can have a noticeable
impact on its operating costs.
Are the steam-generating systems and
turbines in the facility becoming obsolete,
and now require ever-growing
maintenance needs? Owners may have
planned steam-boiler replacement projects
or other equipment maintenance or upgrades.
If so, owners may want to consider if
this investment may be better spent on electrification.
Overall equipment reliability may
increase and there may be environmental
credits or rebates that can be availed with
electrification projects.
Is the facility in compliance with local
regulations on pollutant emissions?
Owners may be facing looming environmental
regulations that will require significant
investments, such as installation of
selective catalytic reduction (SCR) systems
for steam boilers or process heaters, to
avoid paying hefty fines. An electrification
project can reduce steam demand and potentially
allow the shutdown of older steam
boilers, therefore reducing the cost of any
required
environmental
upgrades.
The
its peak
emissions reductions from the decrease in
steam demand resulting from electrification
can also be used to offset an increase in
emissions from other process heaters with
process changes that can be valuable for
other strategic goals.
Are the utility systems at capacity, or
Peak energy efficiency?
Aging equipment/reliability?
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Chemical Engineering April 2023

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