Power-to-Heat in practice

The electrification of industrial process heat is rapidly gaining importance. More and more companies are faced with the task of converting their heat supply to electricity and integrating renewable energy sources.

However, the real challenge is not simply switching to electricity. The key question is: How can security of supply, cost-effectiveness and flexibility be ensured at the same time? Modern production processes require a heat supply that is reliably available at all times, adapts flexibly to changing loads and, at the same time, meets increasing energy efficiency requirements.

Why the right system concept makes all the difference

A reliable Power-to-Heat concept converts electrical energy – whether from the public grid or from a company’s own renewable energy sources – directly into precise process heat. However, the decisive added value for operations does not lie in the heat generator alone. It is only the combination of intelligent control, precise regulation and well-thought-out planning that makes electrification an economical and worry-free solution.

For the transition to work smoothly in day-to-day operations, four key factors are essential:

Compatible with the existing infrastructure

Whether for low power requirements or applications in the megawatt range, the system must be compatible with the plant’s electrical infrastructure. For low to medium power requirements, the proven 400 V grid is used. For large industrial systems in the megawatt range, using 690 V is often advantageous: cabling requirements, space requirements and specific costs are reduced.

Protection against failures and a long service life

To prevent the components used from wearing out prematurely, intelligent electronics control the system. The heating elements are switched on and off in rotation so that all components are subjected to an even load. In addition, the current of each individual heating element is continuously monitored. This allows irregularities to be detected at an early stage, protects against unplanned production downtime and ensures maximum availability.

Actively reducing electricity costs

A modern system dynamically adjusts its heating output. If the process heat demand changes or electricity prices on the market fluctuate, the control system reacts automatically. This allows periods of low electricity prices on the market or surplus electricity from the company’s own photovoltaic system to be used selectively in order to noticeably reduce operating costs.

Fast implementation without long waiting times

Since the heat is generated electrically and therefore completely emission-free directly at the process, there is no need for chimneys, fuel storage or time-consuming emissions-related approval procedures. Pre-assembled complete systems on a base frame (“Plug & Heat”) also reduce on-site installation work to a minimum.

Proven in practice

Numerous NESS systems that have already been implemented demonstrate that these concepts work smoothly in everyday industrial operations:

• Wood-based panel industry:

A 3.1 MW system whose control system responds specifically to external electricity price signals. The result is a highly flexible operating mode that makes optimum use of volatile energy prices.

• Chemical industry:

A hybrid system consisting of an electric heater (800 kW) and an existing gas-fired boiler (1 MW) jointly secures the heat supply.

• Aerospace industry:

A 1,000 kW electric heater operates in parallel with a fired heater, thereby increasing security of supply.

• Wood-based panel industry:

Currently equipped with 1,240 kW and expandable to 3.1 MW. Until the planned expansion, the heater is already supporting heat demand elsewhere. Instead of remaining unused, it therefore creates added value from the outset.

The electrification of industrial process heat means far more than simply replacing a heat generator. It requires a well-thought-out overall concept that combines cost-effectiveness, flexibility and operational reliability. With individually designed Power-to-Heat solutions, such as those developed by specialists like NESS, companies can successfully transition to a future-proof heat supply without compromising ongoing operations.