The Thermal Loop Revolution

Volker Metzger, Watlow, Germany, discusses the challenges and opportunities of lowering carbon emissions in the oil and gas industry through electrification.

The necessity for electrification in industrial processes has intensified as the world aims to fulfill the objectives set by international agreements on climate change. Many traditional industries, such as oil and gas, still rely on gas burners or steam rather than electric heaters. However, electrification plays a key role in advancing thermal systems within industry and lowering greenhouse gas emissions (GHG).

Trends in industrial electrification

The global shift towards decarbonisation, driven by regulatory pressures and sustainability goals, is pushing the oil and gas industry to transition from fossil fuel-based heating systems to electric heating systems. This trend is evident in the implementation of electric heaters in various oil and gas operations, including refineries, petrochemical plants, and gas processing facilities.

The 2015 Paris Agreement and subsequent regulations such as the 2021 Dutch court ruling against Shell, which mandated a 45% reduction in carbon emissions, have significantly accelerated this transition. A key strategy to meet these targets is to replace traditional gas-fired process heaters with electric alternatives.

The adoption of electric heating systems in the oil and gas sector is driven not only by regulatory compliance, but also by the need for enhanced process control and operational efficiency. Electric heaters offer precise temperature control and can be integrated with renewable energy sources, making them a sustainable option for modern industrial applications.

However, any electrification of processes needs to be economically viable, and many companies need support in understanding the benefits of electric heaters. So, what is the way forward for electrification and how does the latest technology support this approach?

Advanced heater technology

Medium voltage electric heaters

Medium voltage electric heaters are designed to handle the high-power requirements of industrial applications while providing greater efficiency and safety. These heaters can operate at up to 7200 V, significantly reducing the need for large step-down transformers and extensive cabling. This not only lowers installation and maintenance costs, but also minimises the heat generated by cabling inside the heater enclosure and control panel.

Medium voltage heaters are particularly beneficial for applications requiring high wattage, such as crude oil heaters and LNG vaporisers. They offer improved thermal efficiency and uniform heat distribution, which is critical for maintaining process integrity and reducing energy consumption.

Continuous flow

Continuous Helical Flow TechnologyTM is a revolutionary design that eliminates the dead zones often found in traditional heaters. These dead zones can lead to hotspots, causing coking and fouling, which require frequent maintenance and can disrupt operations. By ensuring a uniform temperature distribution across the heating surface, this technology significantly reduces the likelihood of fouling and extends the heater’s operational life.

Continuous helical flow technology is especially useful in processes that involve heating viscous fluids or those that are prone to fouling. The consistent flow and temperature distribution help maintain optimal process conditions and reduce the need for frequent cleaning and maintenance.

High-efficiency heat exchangers

The latest high-efficiency heat exchangers incorporate advanced materials and design principles to maximise heat transfer while minimising pressure drop. Innovations such as the OPTIMAX® heat exchanger combine optimal fluid dynamics with efficient heat transfer in a compact design, reducing the overall footprint of the heating system.

These heat exchangers are designed to handle a wide range of industrial applications, including those within the oil and gas sector. They offer excellent performance in terms of thermal efficiency and reliability, making them sustainable for processes that require precise temperature control and high efficiency.

Advanced power control systems

Modern electric heaters are equipped with advanced power control systems that provide precise control over the heating process. These systems use proportional-integral-derivative (PID) controllers to adjust the power output based on real-time temperature data, ensuring stable and accurate temperature control.

Additionally, these power control systems can be integrated with data management tools to provide insights into energy consumption, system health, and performance trends. This enables predictive maintenance and helps operators to optimise their heating processes for maximum efficiency and reliability.

Safety

Safety is a paramount concern in the oil and gas industry, particularly when dealing with high-voltage equipment. Arc flash mitigation technologies are designed to detect and respond to arc flash events quickly, reducing the duration and energy of the event. Optical arc detection systems use photoelectric sensors to detect the intense light from an arc flash and trip the circuit breaker within milliseconds, minimising the risk of injury and damage.

Ensuring safety in electrified systems also involves designing control systems that can isolate faults and prevent cascading failures. This is particularly important in medium-voltage systems, where the energy levels are high enough to cause significant harm if not properly managed.

Additionally, implementing robust training programmes for personnel on the safe handling and operation of

medium-voltage equipment is crucial. This includes understanding the risks associated with arc flash events and the correct use of personal protective equipment (PPE).

Data-driven optimisation

Data insights are transforming the efficiency and sustainability of thermal systems within the oil and gas industry. Predictive control, enabled by data analytics, allows for real-time monitoring and optimisation of heating processes. For instance, thermal systems equipped with advanced data insights can provide comprehensive monitoring of system power, controller health, and process changes, helping to prevent issues such as coking, fouling, and heater failure.

These data-driven approaches facilitate proactive maintenance, reducing downtime and improving overall system reliability. By analysing temperature drift and power consumption patterns, oil and gas facilities can enhance process efficiency and extend the life of their equipment.

Data-driven optimisation also includes the ability to monitor environmental conditions and terminal temperatures within control panels, ensuring the overall health and efficiency of the thermal system. This kind of integrated monitoring allows for timely interventions that can prevent unplanned shutdowns and maintain optimal operation.

The use of advanced algorithms in data analysis can further enhance predictive maintenance capabilities. For example, machine learning models can identify patterns and anomalies in the thermal data that human operators might miss, enabling even more precise control and early detection of potential failures.

Integration challenges

Integrating electric heating into existing oil and gas facilities presents several challenges, including space constraints, compatibility with existing infrastructure, and the need for significant electrical upgrades. Many facilities are designed around gas-fired heaters and require substantial modifications to accommodate electric systems.

One major challenge in older facilities with limited space is the physical space required for new electrical components, such as transformers and control panels. Upgrading the electrical infrastructure to support high-wattage electric heaters also often involves complex planning and coordination to ensure that the power supply is adequate and reliable.

Addressing these challenges requires a comprehensive approach that considers the entire thermal loop: from heaters and sensors to controllers and data management. By viewing the system as a whole, rather than as individual components, oil and gas facilities can better plan and execute the integration of electric heating systems, ensuring compatibility and optimising performance.

Advanced simulation tools can be used to model the thermal and electrical behaviour of the system before actual implementation. These help identify potential issues and ensure the design is optimised for better performance and reliability.

The thermal loop concept

The thermal loop concept embodies a systems-thinking approach to thermal management. A typical thermal loop includes components such as high-efficiency heaters, advanced temperature sensors, and intelligent controllers that adjust power output based on real-time data. By integrating these components, oil and gas facilities can achieve exacting temperature requirements, reduce energy consumption, and enhance process reliability.

Considering the design of the entire thermal loop allows for better scalability and flexibility, enabling facilities to adapt their thermal systems to changing process demands and regulatory requirements. By continuously monitoring and adjusting the system, the thermal loop can maintain optimal performance under varying conditions, providing a robust solution for modern industrial needs.

Advanced thermal loop systems can also incorporate cybersecurity measures to protect against data breaches and ensure the integrity of the control systems. This is especially important in industries where data security is critical, such as oil and gas.

Conclusion

As regulatory pressures and environmental concerns continue to mount, the shift towards electrification will play an increasingly critical role within the oil and gas industry. With the right partner, the benefits of leveraging data-driven insights, advanced safety measures, and taking a comprehensive systems approach can be realised, enabling facilities to transition to cleaner, more efficient electric heating solutions.

Electrification is not without its challenges, but with the right strategies and technologies, the oil and gas industry can overcome these obstacles and realise the many benefits that it has to offer. The future lies in the integration of electric systems that are safe, efficient, and sustainable, paving the way for cleaner, efficient, and resilient thermal processes within the industry.