Optimisation and decarbonisation of industrial heating processes with electric thermal oil boilers. Carles Ferrer September 2024

In recent years, the implementation of electric thermal oil boilers has gained popularity in the industrial field, in line with the growing trend towards electrification and process decarbonization.
These boilers allow a transition to more sustainable heating processes, especially in those systems that operate with thermal fluids.

It is important to note that the impact on decarbonization is closely linked to the source of the electricity used.
If it comes from renewable sources, the environmental benefit is considerable; otherwise, if electricity is generated from fossil fuels, the reduction in emissions will be less pronounced.

Economic and Environmental Benefits

The transition to electric thermal oil boilers responds to two main motivations: cost reduction and minimization of environmental impact.
• Reduced Operating Costs: Electric boilers typically involve lower operating costs due to their low maintenance and elimination of the need to handle and store hazardous fuels.
In addition, in scenarios where the cost of electricity is lower than that of gas, the savings in operating costs are even more significant.
• Industrial Decarbonization: The replacement of combustion boilers with electric boilers contributes to reducing emissions of carbon dioxide and other pollutants, since the combustion of fossil fuels is eliminated.
This results in a direct reduction in CO₂ emissions and other greenhouse gases, which is crucial for decarbonization goals.

Environmental Impact of the Transition

The transition to electric thermal oil boilers can have a significant environmental impact for a company, contributing positively in several aspects:
• Reduction of Greenhouse Gas Emissions.
This is particularly relevant in industries with high thermal demands, where change can result in a considerable reduction in the carbon footprint.
• Combustion boilers emit not only CO₂, but can also emit, in certain cases, nitrogen oxides (NOx), particulate matter and volatile organic compounds (VOCs), which are harmful to health and the environment.
By opting for electric boilers, these emissions are eliminated, improving air quality and reducing the local environmental impact.
• As mentioned, if the electricity used comes from renewable sources, such as solar, wind or hydroelectric energy, the transition to electric boilers reinforces the company’s commitment to sustainability, aligning with global carbon reduction targets.
• By operating with electricity, dependence on non-renewable natural resources is reduced, which contributes to the preservation of these resources and reduces the pressure on ecosystems associated with their extraction.
• Combustion boilers require the handling and storage of fuels, which implies risks of spills and generation of hazardous waste.
Electric boilers eliminate these risks, contributing to cleaner and safer operation.

Additional Advantages of Electric Boilers

Beyond the economic and environmental benefits, electric thermal oil boilers offer a number of additional advantages that improve operational efficiency and flexibility:
• Greater Energy Efficiency: These boilers require less energy to generate the same level of heat as their combustion counterparts, which translates into lower energy consumption and, therefore, a decrease in emissions.
• Reduction of Pollutants: By not depending on combustion, emissions of nitrogen oxides, particles and volatile organic compounds, common in traditional boilers, are eliminated.
• Space Optimization: Electric boilers take up less space and offer greater flexibility in their location, as they do not need infrastructure for fuel storage.
• Control and Automation: These boilers allow for more precise control of heat production, which optimizes energy efficiency and is better adapted to the specific needs of each process.
• Regulatory Compliance: They help companies comply with current environmental regulations, avoiding sanctions and fines.

Key Considerations for the Transition

Before replacing a combustion boiler with an electric one, it is crucial to carry out a thorough analysis to ensure that the new installation will meet expectations in terms of efficiency and performance:
• Heat Demand Assessment: The electric boiler must efficiently meet the required thermal demand.
• Cost Comparison: It is essential to compare the investment and operating costs of both technologies, considering electricity prices and maintenance costs.
• Electrical Capacity: Check if the existing electrical infrastructure can support the additional load or if improvements need to be made.
• Regulations and Standards: It is essential to know the regulations applicable to the installation and operation of electric boilers, including permits, safety standards and emissions.
• Impact on Production: Analyze how the transition will affect production capacity and integration with existing heating systems.
• Life Cycle Analysis: Consider the environmental impact throughout the full life cycle of both options, from manufacturing to decommissioning.

An informed decision requires the collaboration of engineers and consultants specialized in industrial energy, who can perform a detailed analysis and provide the necessary technical advice.

Hybrid Systems: Boiler Combination

In some cases, the best option may be a hybrid system, which combines electric and combustion boilers in parallel.
This configuration allows you to take advantage of the advantages of both technologies, optimizing efficiency and operational flexibility.

The implementation of a hybrid system must be supported by a detailed engineering analysis, which considers boiler compatibility, electrical infrastructure, and operating costs.
With proper design and planning, boilers can be ensured to operate optimally, contributing to efficiency and decarbonization goals.

Innovation through intelligent systems

The development of intelligent systems that automatically adjust boiler operation based on energy prices offers new opportunities to optimize costs and efficiency.
These systems can decide which boiler to activate according to which is the most economical and sustainable energy source at any given time, which not only reduces operating costs but also contributes to decarbonization, especially when renewable energy sources are prioritized.

This innovative approach promises better control, automation, and more efficient operation, aligned with the changing needs of modern industry.

More information about thermal oil boilers at this link

Carles Ferrer, Commercial Director of Pirobloc
Pirobloc is a member of the Private Business and Climate Foundation