To truly understand the challenges and opportunities for reducing emissions through electrification, it’s essential to examine the current state of air quality. As a case in point, consider the South Coast Air Basin, which includes extensive parts of Los Angeles, Riverside and San Bernardino counties as well as all of Orange County. This area is widely recognized as the most ozone-polluted regions in the United States.
The South Coast Air Basin amended Rule 1147, which is aimed at reducing nitrogen oxide (NOx) emissions from combustion systems across various industries, focuses on ensuring compliance with regional air quality standards and is part of broader efforts to meet federal and state ozone and particulate matter standards. While electrification is not explicitly mentioned in the rule itself, electrification is an increasingly viable option for achieving compliance and furthering air quality goals.
Traditional combustion equipment is typically fueled by fossil gas which emits high levels of harmful emissions. Retrofitting and replacing burners may reduce NOx emissions, but switching to electric heating systems could be a more effective long-term solution for facilities. In addition, electrification could align with California’s statewide push to meet its ambitious carbon neutrality goals by 2045.
Electrification, when paired with other measures like renewable energy adoption, supports compliance with the spirit of the regulation, especially for facilities that are looking to modernize and reduce both NOx and greenhouse gas emissions. Electrification is not only complementary to Rule 1147’s objectives, it can also help facilities meet future regulatory and environmental goals in a more sustainable way.
But first, it’s important to understand that there is no one-size-fits-all electrification solution. And it isn’t right for every operation or every system. We advise clients to assess their readiness by first ensuring they have the right data. Start by using digital recorders to monitor process parameters, ensuring you can accurately determine energy demands and temperature requirements. This groundwork is vital for evaluating electrification potential.
Ideal applications for electrification
Electrification is particularly effective for systems operating in lower temperature ranges, typically below 1200°F, where electric heating elements perform reliably without rapid degradation. Examples of such applications include:
- Curing ovens: Common in automotive and aerospace industries for processes like composite curing, where consistent temperatures around 450°F are maintained for precision results.
- Paint booths: For baking and curing paint in manufacturing lines, electrification offers a cleaner and more controllable process.
- Drying and post-processing systems: Often required after manufacturing to finalize material properties.
Benefits of electrification
Transitioning to electrification offers several advantages for industrial companies, such as:
- Enhanced process control. Electrification provides infinite turndown ratios, allowing precise control over heating cycles and airflow via VFDs (variable frequency drives).
- Reduced maintenance costs. Electric systems have fewer moving parts, reducing wear and repair needs.
- Regulatory compliance. Electrification eliminates NOx and CO emissions, eliminating the need for compliance with the regulatory agency in your region and its associated costs.
- Sustainability goals. Electrification supports carbon neutrality by removing fossil fuel dependency.
Electrification challenges to consider
Electrification requires careful planning and investment in infrastructure:
- Power requirements. Facilities may need to upgrade wiring and ensure adequate power capacity for high-amperage systems.
- Temperature and material compatibility. Electrification is not recommended for processes requiring temperatures above 1200°F due to the potential degradation of electric heating elements.
- Initial costs. Infrastructure modifications can represent a significant upfront investment.
At George T. Hall Company, we have expertise in both combustion and electric heating systems, offering tailored solutions for electrification projects. We partner with innovators in the electrification space to ensure advanced, efficient and reliable electric heating systems. Whether you’re upgrading existing systems or designing new ones, our UL508A and UL698A-certified control panels, and in-depth knowledge ensure seamless transitions and optimized performance.
Ron Heintskill is senior project engineer at George T. Hall Company, a certified member of the Control System Integrators Association (CSIA). For more information about George T. Hall Company, visit its profile on the CSIA Industrial Automation Exchange.
