Industry

Process Heat

Process heat is the heat required for numerous technical processes and procedures in trade and industry. Unlike room heat, process heat is available at a considerably higher temperature level, which is optimised for each application. Process heat is necessary for cooking, baking, sterilising, drying, smelting, forging, welding and producing steam. Due to the high temperature level of process heat, it is generally not possible to use waste heat from other processes, which means that process heat is generated by combustion processes or electricity. 40% of the energy used in Germany is consumed in trade and industry and in the services sector. Approximately 66% of industrial energy consumption is required to generate process heat. Therefore, this is a large area of activity in which measures can be taken to save energy. Approximately half of all process heat required is below 300 °C / 572 °F; the remaining half is below 180 °C / 356 °F.

Generally, the greatest energy savings potential for reducing costs is to change the energy resource from electricity to gas. This generally cuts down on CO2. However, it does not necessarily reduce the quantity of energy required i.e. simply changing from one energy resource to another does not automatically increase the efficiency of a process. Increased energy efficiency is mostly achieved by optimising the system technology. Potential energy savings can be attained, for example, by using energy-saving motors. This improves energy efficiency and reduces losses. The use of combined heat and power (CHP) or combined cooling and power (CCP) should also be considered. Poor insulation is frequently associated with energy loss. Heat recovery is an important consideration for potential energy savings. When smelting metals, it makes sense to constantly monitor the smelting temperature and adjust the smelting cycle to the throughput of the casting machine. First and foremost, a policy of efficient load management should be adopted. The total energy savings potential is at least 15%. Process heat can also be generated using solar energy. This is of particular interest, given the rising energy prices and the reduction of greenhouse gas emissions. Germany is working intensively on the further development of solar process heat. Possible areas of application include agricultural drying plants and industrial operations such as washing, cooking, drying and pasteurisation. Solar energy can also be used for processes at high temperatures.