Introduction

Industrial heat processes, traditionally reliant on fossil fuels, represent a significant portion of global energy consumption and a major source of greenhouse gas emissions. As industries strive to achieve ambitious decarbonization targets and enhance operational efficiency, the electrification of industrial heat processes emerges as a pivotal strategy. This paradigm shift involves replacing combustion-based heating with advanced electric technologies, offering not only substantial reductions in carbon footprint but also benefits such as improved process control, enhanced product quality, reduced maintenance, and a safer work environment. The successful transition to electrified industrial heat requires a deep understanding of various electric heating technologies, their suitability for different temperature ranges, integration with renewable energy sources, and the necessary electrical infrastructure upgrades. Without strategic planning and expertise in Electrification of Industrial Heat Processes, industrial facilities risk lagging behind sustainability goals, incurring higher operational costs, and missing out on the competitive advantages of a modernized, cleaner production system, underscoring the vital need for specialized training in this transformative area. This comprehensive training course focuses on equipping professionals with the expertise to master Electrification of Industrial Heat Processes.

This training course is meticulously designed to empower industrial engineers, plant managers, energy managers, process engineers, electrical engineers, sustainability professionals, and decision-makers within manufacturing and industrial sectors with the theoretical understanding and practical insights necessary to effectively evaluate, plan, and implement the electrification of industrial heat processes. Participants will gain a comprehensive understanding of diverse electric heating technologies, including industrial heat pumps, electric boilers, induction heating, and resistance heating, and learn to assess their applicability across various industrial temperature requirements. The course will delve into topics such as waste heat recovery optimization, integration with renewable electricity sources, power system requirements for electrification, economic feasibility analysis, and the development of tailored electrification roadmaps for specific industrial facilities. By mastering the principles and practical application of Electrification of Industrial Heat Processes, participants will be prepared to drive significant energy efficiency gains, achieve substantial emission reductions, enhance operational flexibility, and contribute significantly to building a sustainable and competitive industrial future.

Duration: 5 Days

Target Audience

• Industrial Engineers
• Plant and Operations Managers
• Energy Managers in Industrial Facilities
• Process Engineers
• Electrical Engineers (Industrial Sector)
• Sustainability and Environmental Professionals
• Manufacturing Executives and Decision Makers
• Maintenance Engineers
• Consultants in Industrial Energy Efficiency
• Researchers in Industrial Decarbonization

Objectives

• Understand the drivers and benefits of electrifying industrial heat processes.
• Learn about the range of electric heating technologies applicable to industrial processes.
• Acquire skills in assessing the suitability of different electric heating solutions for various temperature demands.
• Comprehend techniques for optimizing energy efficiency through electrification and heat recovery.
• Explore strategies for integrating renewable electricity sources with industrial heat processes.
• Understand the power system requirements and upgrades needed for industrial electrification.
• Gain insights into the economic analysis and business case development for electrification projects.
• Develop a practical understanding of planning and implementing an industrial heat electrification roadmap.

Course Content

Module 1: Introduction to Industrial Heat and Decarbonization Imperatives

• Overview of industrial energy consumption and GHG emissions.
• The critical role of process heat in industrial operations.
• Drivers for industrial decarbonization: climate targets, regulations, economic benefits.
• The concept of "beneficial electrification" in industry.
• Barriers and opportunities for industrial heat electrification.

Module 2: Industrial Heat Electrification Technologies Overview

• Electric boilers (electrode boilers, resistance boilers) for steam and hot water.
• Industrial heat pumps for low to medium temperature heat recovery and supply.
• Induction heating for precise and high-temperature applications.
• Resistance heating elements and furnaces.
• Microwave and infrared heating technologies for specific processes.

Module 3: Industrial Heat Pumps: Principles and Applications

• Working principles of industrial heat pumps (coefficient of performance - COP).
• Types of industrial heat pumps: vapor compression, absorption, mechanical vapor recompression (MVR).
• Applications across various industries (food & beverage, pulp & paper, chemical).
• Leveraging waste heat recovery with heat pumps.
• Design considerations and sizing of industrial heat pumps.

Module 4: Electric Boilers and Steam System Electrification

• Efficiency and advantages of electric boilers compared to fossil fuel boilers.
• Direct electric boilers vs. electrode boilers.
• Integration of electric boilers into existing steam networks.
• Strategies for optimizing steam demand and distribution.
• Case studies of electric boiler deployment in industry.

Module 5: High-Temperature Electrification: Induction, Resistance, and Advanced Heating

• Principles and applications of induction heating for metals and materials processing.
• Resistance heating furnaces and ovens for various industrial processes.
• Arc furnaces for high-temperature applications (e.g., steelmaking).
• Plasma torch applications for ultra-high temperatures.
• Opportunities and challenges for high-temperature electrification.

Module 6: Energy Efficiency and System Integration

• Comprehensive energy auditing for industrial heat processes.
• Waste heat recovery techniques beyond heat pumps.
• Process optimization for reduced heat demand.
• Integration of electrified heat solutions into existing industrial infrastructure.
• Benefits of electrification for precise process control and product quality.

Module 7: Power Supply and Grid Integration for Industrial Electrification

• Assessing existing electrical infrastructure capacity for increased load.
• Requirements for substation upgrades and new electrical connections.
• Power quality considerations (harmonics, power factor).
• Integrating renewable electricity sources (on-site or grid-supplied renewables).
• Smart energy management and demand response strategies for electrified loads.

Module 8: Economic Analysis, Project Planning, and Roadmapping

• Cost-benefit analysis for industrial heat electrification projects.
• Calculating payback periods and return on investment (ROI).
• Available incentives, subsidies, and funding mechanisms.
• Developing a phased roadmap for industrial heat electrification.
• Risk assessment and mitigation strategies for electrification projects.

Training Approach

This course will be delivered by our skilled trainers who have vast knowledge and experience as expert professionals in the fields. The course is taught in English and through a mix of theory, practical activities, group discussion and case studies. Course manuals and additional training materials will be provided to the participants upon completion of the training.

Tailor-Made Course

This course can also be tailor-made to meet organization requirement. For further inquiries, please contact us on: Email: info@skillsforafrica.org, training@skillsforafrica.org  Tel: +254 702 249 449

Training Venue

The training will be held at our Skills for Africa Training Institute Training Centre. We also offer training for a group at requested location all over the world. The course fee covers the course tuition, training materials, two break refreshments, and buffet lunch.

Visa application, travel expenses, airport transfers, dinners, accommodation, insurance, and other personal expenses are catered by the participant

Certification

Participants will be issued with Skills for Africa Training Institute certificate upon completion of this course.

Airport Pickup and Accommodation

Airport pickup and accommodation is arranged upon request. For booking contact our Training Coordinator through Email: info@skillsforafrica.org, training@skillsforafrica.org  Tel: +254 702 249 449

Terms of Payment: Unless otherwise agreed between the two parties’ payment of the course fee should be done 10 working days before commencement of the training.