HYDRAULICS Industrial heat demand accounts for more than 20% of global energy consumption?. Decarbonising this heat is essential to achieving net-zero targets, and the electrification of a wide range of processes and equipment, from space heating to furnaces, is one of the most practical ways to do it. Electrification can also deliver benefits such as improved energy efficiency and lower operating costs?. Industrial heat demand and decarbonisation According to Matt Hale, Global Key Account Director at HRS Heat Exchangers, industrial heat represents a significant share of global energy use, making its decarbonisation a crucial part of the transition to net zero. Electrifying heating processes offers one of the most effective ways to reduce emissions while improving efficiency and cost control. However, the shift to electricity is not without challenges. Hale notes that economic factors, technical limitations, a lack of knowledge, and infrastructure constraints continue to slow progress?. The scale of industrial heat use makes the task even more complex. Industry consumes around 37% of total global energy, two-thirds of which is used for heat generation. Of that, around 80% is still produced by burning fossil fuels?. Research from McKinsey & Company? highlights that manufacturing, food and beverage, and agriculture and forestry are the sectors most dependent on processes requiring lowtemperature heat (below 200 °C). Manufacturing and food and beverage could see the greatest benefits from electrification in the near term, with potential electrification rates of 62% and 44% of total energy demand respectively by 2030. Technologies for the electrification of heat Hale explains that choosing the best technology for electrical heating depends on the temperature required, the holding time, and the process capacity. Established technologies such as mechanical vapour recompression (MVR) and heat pumps can cover a wide temperature range, from 50 °C to over 200 °C. Newer technologies, including e-boilers and turbo heaters, are now reaching commercial maturity and can provide heat up to 500 °C and 1000 °C. Rapid progress is also being made with induction heating, which is increasingly suitable for higher-temperature industrial applications. The speed of heating is another important consideration, and in this respect e-boilers typically respond faster than heat pumps. According to Hale, the market has yet to settle on definitive technological winners, with broad commercial maturity not expected before 2030. Even so, some technologies, such as MVR and ohmic heating, are already proven and are being applied by HRS Heat Exchangers in suitable projects. Ohmic heating Hale highlights ohmic heating as an effective example of how electricity can be used to provide precise and uniform heating. In fruit juice pasteurisation, for instance, the technique has been shown to inactivate bacteria, yeast, and moulds efficiently while maintaining the natural flavour and quality of the product. The HRS Ohmic System passes an electric current between two electrodes as the juice flows through a one-metre ceramic tube. This heats the juice to 105 °C in one second, holds it at that temperature for four seconds, and then cools it. Although ohmic heating is not a new concept, the HRS design uses advanced electronic controls to deliver a very smooth temperature curve, improving both product quality and process efficiency. While the equipment represents a higher capital cost than traditional pasteurisation, and running costs depend on electricity prices, Hale notes that more processors are turning to the technology because of its proven benefits. The ability to produce ‘as fresh’ juice with better taste and shelf life allows many to sell into premium markets, making the investment worthwhile. Mechanical vapour recompression (MVR) Hale also reports growing interest in MVR technology for evaporation, particularly following the volatility of energy 20 HYDRAULICS & PNEUMATICS November/December 2025 www.hpmag.co.uk Electrifying industrial heating and the role of heat exchangers Industrial heating systems depend on precise control of fluid flow and heat transfer. As electrification reshapes energy use, H&P looks at how technologies such as mechanical vapour recompression and ohmic heating are improving hydraulic performance, energy efficiency, and sustainability across industrial processes.
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