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In today’s industrialized world, process heat contributes to almost every industrial process in manufacturing physical goods. About 20% of energy consumed in the US goes towards process heat.
Industrial process heat refers to the thermal energy harnessed and utilized for a variety of operations in industries that require specific heat applications such as manufacturing, chemical processing, and food production. This thermal energy is primarily derived from fuels or electricity and sometimes nuclear reactors. Industrial processes can cover a myriad of important tasks that require varying levels of heat, from simple heating of materials for molding to complex chemical reactions that require very precise temperatures and conditions. Industrial process heat represents a large demand for energy as it facilitates the creation of a wide range of products and materials we rely on daily.
Different industrial activities require different temperature ranges. Desalination and district heating can operate at the lower end of this spectrum with a heat source ranging around 200°C while cement and ceramics can require temperatures as hot as 1650°C.
Combustion fuels are often the default choice when the application requires extreme heat or is simple enough to run from a furnace or burner. The heat from combustion fuels typically offers an advantage over electrical heat based on the cost per thermal energy unit. Electrical heating systems might cost more than combustion sources but tend to be easier to control and require less maintenance. Depending on the setup, electrical heat also has the advantage of simplicity as there are no combustion systems or direct emissions from the heat source to manage.
The three primary categories of heat transfer conduction, convection, and radiation can all be found in various forms across industries. Heat can be directly transferred through conduction like food cooking on a skillet. Many industrial applications take advantage of convection through the use of heated air like food in an air fryer or “convection oven”, while other processes utilize radiative heat like heating food in a microwave.
Heat sources can also be separated from the process applications through the use of heat conduits which often utilize heated water or steam. In many cases, hybrid systems are used to keep the process energy efficient and reduce losses. For instance, a process that requires a very precise high temperature might use gas to heat an oven most of the way and use a complementary electrical heating system to fine-tune the oven to the desired temperature with high precision. Many industrial heaters have a primary gas-powered heat source with a series of electrical heating units that can respond quickly to fluctuating conditions to maintain the ideal target temperature inside each oven zone.
Fuel and chemical production are by far the largest users of process heat. Oil and gas refineries plus coal liquefaction all require immense amounts of heat. Ammonia, which is a central ingredient in the fertilizer that supports modern agriculture, also requires a significant contribution of process heat in its production. Chemical production ranging from plastics to pharmaceuticals can also require a range of process heat applications.
Metallurgical smelting, forging, and treating all typically require process heat at high-temperature ranges. Glass foundries, some ceramic kilns, and cement production tend to require higher-range process heat.
Chemical processing can vary across all ranges as many chemical reactions require different conditions, yet many span across medium-range heat applications. Polymer molding and extruding can also occur in this range depending on the materials involved. Some metals with lower melting points can also be processed in the medium ranges.
The low ranges include many activities that just require heating water like desalination or district heating networks. Low ranges also include most forms of food preparation and processing like baking or grilling. Sterilization methods and routine safety practices can also occur in these ranges such as pasteurization. Distillation can be a useful process in many industrial activities like purifying water, but it is also central to the production of many food ingredients and alcoholic beverages. Textiles and other products that require washing or drying will typically need low-range process heat. Pulp and paper manufacturing will also use low-range heat across the production cycle of making paper goods.
Process heat accounts for 20% of energy consumed in the US so any improvements in energy efficiency are worthy of exploration. (World Nuclear Association, 2021) Increasing energy efficiency can be as simple as insulating the heated components to retain more thermal energy applied to the process. Some improvements can go as far as changing the process or composition of a product in a manner that reduces the required heat without compromising on quality.
If an industrial process requires a particular temperature, directly heating a material to that temperature from one heat source would require spanning the entire differential from the resting temperature to the target temperature. If the material can be cheaply pre-heated well above the initial resting temperature, that would reduce the energy required from the primary heating method to achieve the target temperature. By using cheap thermal energy to reduce the differential between the input and target temperature, the resulting energy savings can translate into cost savings.
Cheap “preheat” can come from cheap industrial sources nearby but it can also come from waste heat recovery of the industrial process itself. Capturing and reusing waste heat generated during industrial processes can improve energy efficiency and thermal management. Waste heat can be recovered using heat exchangers, economizers (dedicated heat pumps) or regenerative burners, and then repurposed for preheating feedwater, air, or other upstream inputs.
Electricity production from thermal plants is one of the most abundant forms of waste heat that could be applied to industrial processes. Every thermal power plant produces waste heat that needs to be removed from the system. This heat can be harnessed for industrial processes, even if the amount recovered is only useful for pre-heating. An industrial park hosting a thermal power plant can set up a local heat network to route high-temperature steam to where it can be used.
In today’s industrialized world, process heat contributes to almost every industrial process in manufacturing physical goods. About 20% of energy consumed in the US goes towards process heat. (World Nuclear Association, 2021)
Process heat plays a significant role in the global energy landscape and is vital to many aspects supporting modern life. As demand for goods and services grows with the global population and more people achieve higher standards of living, the need for industrial process heat will increase with those developments in the coming decades. As a core feature of modern industry, process heat is a key enabler of economic growth, as it supports a foundational aspect of the production of goods and services. Industries that contribute significantly to a country's GDP tend to rely on process heat, these industries enable further economic growth by providing employment opportunities and driving economic development. Industrial process heat is also central to researching, developing, and producing advanced materials and new technologies. Most technological advancements would have never been achieved without process heat, as it is essential for maintaining and improving our modern way of life.
Industrial process heat is a foundational aspect for the majority of industrial applications. The need for process heat spans industries such as chemical processing, food and beverage production, textile production, and manufacturing. Fossil fuels have been the primary source of industrial heat, resulting in substantial fuel costs while also contributing to greenhouse gas emissions and climate change. Continued economic development will need a clean, reliable, and cost-effective thermal energy source to provide heat for industrial uses. Nuclear reactors fitted with steam conduits for direct thermal power offer the most promise for these applications. Nuclear reactors offer plenty of potential for process heat applications. In 2019 there were 79 nuclear reactors worldwide operating in support of desalination, district heating, or process heat. (World Nuclear Association, 2021)
Nuclear energy is recognized as a top contender in overcoming the challenges of climate change due to its ability to provide reliable carbon-free process heat. Process heat is almost always produced with substantial carbon emissions from carbon-based combustion fuels, highlighting a major target for reducing greenhouse gas emissions in the industrial sector. By utilizing nuclear energy as the primary heat source for industrial processes, the industrial sector can reduce the current dependency on fossil fuels.
Transitioning towards clean energy sources is critical for reducing the harmful impacts of pollution and climate change. Nuclear power plants can generate a consistent and substantial amount of electricity and direct process heat, providing a crucial advantage over intermittent renewable energy sources like solar and wind. Reliability is crucial for ensuring energy security and uninterrupted industrial production. Adopting nuclear energy as a carbon-free source of process heat in the industrial sector can help mitigate climate change and reduce adverse effects on the environment.
Some forms of hydrogen production require high temperatures which could be achieved by incorporating nuclear heat sources. The Department of Energy has a development program underway with 4 different nuclear power plants in the US to explore the role nuclear power plants can play in the production of hydrogen. (Department of Energy, 2022)
The compact size of the PWR-20 allows it to be installed in close proximity to a range of industrial facilities that would benefit from a reliable onsite thermal energy source.
Steam conduits are useful for district heating networks which are typically used for general heating of buildings. Industrial parks can also utilize steam conduits for other needs like desalination or process heat applications.
The PWR-20’s modular design enables incremental onsite scaling to meet specific energy requirements. As the energy demands of an industrial park grow, multiple SMRs can be installed as needed, providing flexibility and cost-efficiency.
The heat range offered by the PWR-20 can support the corresponding energy requirements of thermal desalination methods. Steam conduits can provide the heat source for adjacent desalination facilities.
Department of Energy. (2022, November 9). 4 Nuclear Power Plants Gearing Up for Clean Hydrogen Production. Department of Energy. Retrieved March 24, 2023, from https://www.energy.gov/ne/articles/4-nuclear-power-plants-gearing-clean-hydrogen-production
Energy Information Administration. (2022, april). Use of energy in industry - U.S. Energy Information Administration. EIA. Retrieved March 22, 2023, from https://www.eia.gov/energyexplained/use-of-energy/industry.php
World Nuclear Association. (2021, September). Nuclear Process Heat for Industry. World Nuclear Association. Retrieved March 22, 2023, from https://world-nuclear.org/information-library/non-power-nuclear-applications/industry/nuclear-process-heat-for-industry.aspx
