May-2025

Revolutionising process heating for a low carbon world

The industrial sector is at a pivotal juncture as it strives to reduce carbon emissions in alignment with global sustainability goals.

Michael Jones
Watlow

Article Summary

Process heating, an essential element in industries like petrochemicals, food processing, automotive manufacturing, and mining, accounts for a significant portion of industrial carbon dioxide emissions. Transitioning from fossil-fuel-based systems to electric heating provides a promising pathway to achieving decarbonisation. However, this shift introduces technical and operational challenges that require innovative, well-engineered solutions.

Medium voltage (MV) electric heating & control systems, such as Watlow’s POWERSAFE™ thermal system, are emerging as practical and efficient alternatives to traditional systems. These systems address many of the complexities associated with electrification, offering a roadmap for industries seeking to modernise their heating processes and reduce their environmental impact.

The imperative for electrification in industrial heating
Industrial heating processes have historically relied on gas or oil-fired systems and steam-based heat exchangers. While effective, these systems emit substantial greenhouse gases, making them increasingly incompatible with decarbonisation targets and environmental regulations. Electrification provides a cleaner, more sustainable alternative, enabling industries to meet stringent ESG requirements while improving efficiency and reducing long-term costs.

The transition to electrification, however, can be challenging. One of the primary issues is the high cost of retrofitting existing systems, including the installation of necessary electrical infrastructure. Traditional low voltage systems often require extensive copper cabling and large transformers to step down power, adding to installation costs Medium voltage systems, like POWERSAFE, mitigate these issues by operating directly at higher voltage levels, significantly reducing the need for expensive cabling and infrastructure.

By connecting directly to medium voltage power sources (4160-7200V), POWERSAFE systems lower amperage requirements, which translates to reduced copper usage in cables and transformers. This not only lowers material costs but also simplifies installation, making the shift to electrification more Electric duct heater financially feasible for industries seeking to modernise and decarbonise.

Challenges in medium voltage systems and watlow’s solutions
Electrifying industrial heating processes with medium voltage systems presents unique challenges. One critical issue is ensuring the reliability and safety of systems operating at higher voltages, which are more susceptible to electrical phenomena like partial discharge. Partial discharge occurs when small electrical discharges occur within insulating materials due to high electric fields. This can gradually degrade the insulation and compromise system performance. Partial discharge, known as corona partial discharge, can also occur at external sharp points, resulting in high electrical fields.

Watlow’s POWERSAFE system addresses this challenge through advanced engineering of the busbar and connection systems. The busbar system is designed with specific geometric insulating and spacing features to withstand the increased electrical stresses associated with medium voltage applications, preventing the occurrence of partial discharge. By focusing on the durability and robustness of these connections, the

POWERSAFE system has been engineered to ensure long-term reliability and safety, even under demanding industrial conditions.
Another key challenge is maintaining insulation integrity. This issue is particularly problematic for mineral-based insulation materials commonly used in electric heaters, which can absorb water vapor resulting in a drop in megohm resistance of the heater which can ultimate lead to unplanned downtime. However, advanced sealing technologies, such as those used in the POWERSAFE system, effectively prevent moisture ingress, maintaining insulation resistance throughout the product’s lifecycle. This eliminates the need for costly field interventions to dry out heaters, ensuring consistent performance and reducing the risk of operational disruptions.

Temperature capability is another area where medium voltage heaters have faced limitations. Many industrial processes require heating at very high temperatures, and traditional electric systems often struggle to meet these demands. Watlow has addressed this issue with an optimised design that allows for significantly higher temperature thresholds compared to historical heating systems. This expanded capability enables its use in a broader range of applications, giving industries more flexibility in transitioning to electric heating.

Simplifying operations and enhancing efficiency
Beyond addressing the technical challenges of medium voltage heating, POWERSAFE and similar systems offer substantial operational benefits. One of the key advantages of electrification is the simplification of heating systems. Conventional systems that rely on steam or heat transfer fluids require extensive auxiliary equipment, including boilers, piping, and maintenance-intensive infrastructure. Electrified systems eliminate the need for these additional components, allowing for direct heating that reduces complexity and maintenance requirements.

For example, in oil and gas refineries, electrified heaters can replace traditional systems used in charge furnaces, reactor preheaters, and column reboilers. These heaters integrate directly into the process, eliminating auxiliary systems and simplifying plant operations. The reduction in auxiliary equipment not only lowers installation costs but also reduces ongoing maintenance burdens, leading to more streamlined operations and greater reliability.

The reliability of electrified systems is further enhanced through advanced design features. In POWERSAFE, the use of predictive maintenance tools ensures that operators can monitor system performance in real time. Watlow’s THERMALWATCH™ technology, integrated into the POWERSAFE system, continuously analyses parameters such as temperature, pressure, and electrical load. This data-driven approach allows operators to detect potential issues early, preventing unplanned downtime and extending the lifespan of the equipment. In industries where operational continuity is critical, this capability is invaluable.

Addressing power management and grid stability
Electrification of industrial heating also introduces challenges related to power management. High-power systems operating in the megawatt range can place significant demands on electrical supply systems, raising concerns about stability and the potential for power disruptions. Without proper load management, the sudden activation or deactivation of such systems could adversely impact other operations or exceed the capacity of the power grid. The design of the power supply substation and the control system must also be carefully analysed to assure overall power supply stability.

Conclusion
As industries continue to pursue sustainability goals, electrified heating systems offer a practical and scalable solution for reducing emissions and improving operational efficiency. Through advancements in busbar design, insulation integrity, and temperature capabilities, the POWERSAFE system resolves many of the reliability concerns that have historically limited the adoption of medium voltage systems. Its ability to simplify operations, enhance reliability, and integrate predictive maintenance tools ensures that electrified heating systems meet the high demands of modern industrial processes.

Moreover, by reducing copper usage and infrastructure complexity, POWERSAFE demonstrates that electrification can be cost-effective as well as environmentally sustainable. Its design philosophy reflects a broader trend in the industry: the shift toward standardised yet flexible systems that can be tailored to specific applications while maintaining compatibility across multiple sites.

While the transition to electrification presents challenges, modern electrical solutions address these obstacles through thoughtful engineering and innovation, providing industries with a reliable and efficient pathway to electrified heating. By focusing on reliability, efficiency, and scalability, electrified systems are not just a tool for decarbonisation – they are a cornerstone of the future of industrial operations.