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Technical Trends, Radical Innovation, and the Economics of Sustainable, Industrial-Scale Electric Heating for Energy Efficiency and Water Savings

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  • A. A. Vissa

    (MHI Inc., Cincinnati, OH 45215, USA)

  • J. A. Sekhar

    (MHI Inc., Cincinnati, OH 45215, USA
    College of Engineering, University of Cincinnati, Cincinnati, OH 45221, USA)

Abstract

This article examines the energy efficiency and climate impact of various heating methods commonly employed across industrial sectors. Fossil fuel combustion heat sources, which are predominantly employed for industrial heating, contribute significantly to atmospheric pollution and associated asset losses. The electrification of industrial heating has the potential to substantially reduce the total energy consumed in industrial heating processes and significantly mitigate the rate of global warming. Advances in electrical heating technologies are driven by enhanced energy conversion, compactness, and precision control capabilities, ensuring attractive financial payback periods for clean, energy-efficient equipment. These advancements stem from the use of improved performance materials, process optimization, and waste heat utilization practices, particularly at high temperatures. The technical challenges associated with large-scale, heavy-duty electric process heating are addressed through the novel innovations discussed in this article. Electrification and the corresponding energy efficiency improvements reduce the water consumed for industrial steam requirements. The article reviews new technologies that replace conventional process gas heaters and pressure boilers with efficient electric process gas heaters and instant steam generators, operating in the high kilowatt and megawatt power ranges with very high-temperature capabilities. Financial payback calculations for energy-optimized processes are illustrated with examples encompassing a range of comparative energy costs across various temperatures. The economics and implications of waste heat utilization are also examined in this article. Additionally, the role of futuristic, radical technical innovations is evaluated as a sustainable pathway that can significantly lower energy consumption without compromising performance objectives. The potential for a new paradigm of self-organization in processes and final usage objectives is briefly explored for sustainable innovations in thermal engineering and materials development. The policy implications and early adoption of large-scale, energy-efficient thermal electrification are discussed in the context of temperature segmentation for industrial-scale processes and climate-driven asset losses. Policy shifts towards incentivizing energy efficiency at the manufacturing level of heater use are recommended as a pathway for deep decarbonization.

Suggested Citation

  • A. A. Vissa & J. A. Sekhar, 2025. "Technical Trends, Radical Innovation, and the Economics of Sustainable, Industrial-Scale Electric Heating for Energy Efficiency and Water Savings," Sustainability, MDPI, vol. 17(13), pages 1-35, June.
    • Handle: RePEc:gam:jsusta:v:17:y:2025:i:13:p:5916-:d:1688701
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    References listed on IDEAS

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