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

The energy efficiencies of various heating methods commonly used across industrial sectors are explored. The fossil fuel combustion heat sources typically used for industrial heating account for significant atmospheric pollution. The impact of fossil fuel-enabled industrial heating on the tropospheric CO2 levels is discussed. The electrification of industrial heating can significantly mitigate climate change. Advances in alternative sustainable heating processes are driven by improved energy conversion, precision control of processes because of electrification, and the related financial payback period. These advancements are related to improved materials, process optimization, and waste heat utilization practices at higher temperatures. The technical challenges of large-scale, heavy-duty electric process heating are addressed through novel innovations discussed in the article. Electrification and energy efficiency improvements have led to savings in the amount of water used for industrial electric steam generators that replace pressure boilers, thus further adding to the sustainability benefits of electrification of industrial heating devices. The financial payback calculations for energy-optimized processes are illustrated with examples. The article additionally examines the role of futuristic radical technical innovation as a sustainable pathway that can significantly reduce energy use without compromising performance objectives. The possibility of a new paradigm for self-organization across a process and the final use objectives is briefly explored as a possibility for sustainable innovations in thermal engineering and materials development.