ERTC 2025
Electrification: transforming refining for a greener future
Devan Pillay Schneider Electric
Process electrification is reshaping the energy and chemicals sectors, fast-tracking the shift to sustainability and digitally opti- mised operations. Schneider Electric under- stands that decarbonisation demands bold innovation, smart investment, and a fresh look at traditional methods. However, industrial electrification is more than an ambition; it is essential. Unlocking the efficiencies we seek demands a unified strategy for orchestrating molecules and electrons together. To be truly effective, the worlds of electrification and industrial auto- mation must coexist, especially in hard-to- abate sectors where complexity and energy intensity are highest. By replacing fossil fuel systems with effi- cient, electric alternatives, industries can boost performance, reduce emissions, and build resilience. With deep expertise in energy management, industrial automation, and cutting-edge digitalisation solutions, Schneider Electric is ready to guide indus- tries through this transition and unlock the full potential of electrification. The Case for Process Electrification Electrification presents a powerful oppor- tunity for the refining and petrochemical industries to boost efficiency and cut emis- sions. Much of the energy used in these sectors comes from burning fossil fuels for process heating, mechanical drives, and other operations. Switching to electricity- powered systems can deliver major gains in both performance and sustainability. Technologies such as electric heat pumps, mechanical vapour recompression (MVR), and electric furnaces are already proving their industrial worth. Electric heat pumps, for example, can replace traditional reboil- ers and condensers, generating low- and medium-temperature heat with far greater efficiency. MVR systems are improving energy use and reliability in evaporation processes. Electric furnaces are another promising technology for high-temperature applica- tions. While they are not yet commercially available for all processes, electric heating is a mature technology, and advancements are being made. The glass industry already uses electric furnaces exceeding 1,100°C, and companies like BASF are developing electric cracking furnaces for petrochemical appli- cations at around 850°C. Electrification is
also advancing in mechanical drives, where large electric motors with variable speed drives (VSDs) offer improved control, reliabil- ity, and flexibility. The benefits of process electrification go beyond operational efficiency. These tech- nologies reduce maintenance costs, ena- ble remote monitoring, and enhance safety. Additionally, when paired with renewable energy, electrified systems can dramatically lower carbon footprints, supporting long- term sustainability goals. Challenges and Solutions in Electrification While the potential benefits of electrification are immense, several challenges must be addressed to enable its widespread adop- tion in industrial applications. Chief among these are the availability of low-carbon elec- tricity, cost, and electrical infrastructure constraints. Electricity sourcing is a key decision. Grid power must be reliable and low-carbon, while on-site generation – via renewables or high-efficiency combined-cycle plants with carbon capture (CCUS) – can offer greater control and flexibility. The economics of electricity is another factor. Industrial electricity prices can fluc- tuate significantly, and in some cases, they may render electrification less economically viable compared to fossil fuels. For exam- ple, in remote gas fields, using project gas for turbines may be more practical, though it does little to reduce emissions and con- tributes to methane emissions. A promising approach is flexible electrifi- cation. By integrating hybrid systems that combine electric and gas-powered technol- ogies, industries can optimise their energy use based on real-time electricity prices and availability. For instance, during periods of low electricity costs or abundant renewable power, electric systems can be prioritised. Conversely, when electricity is expensive or scarce, natural gas systems can step in, ensuring operational continuity while man- aging costs and emissions. Renewable integration is also critical. Investing in on-site solar or wind, supported by energy storage and grid upgrades, can help overcome intermittency and ensure reliable, clean power for electrified pro- cesses. These efforts must be supported by advancements in energy storage tech- nologies and grid infrastructure to ensure
is set to become a cornerstone of industrial transformation. Realising its full potential will require forward-thinking design, targeted investment, and a culture of innovation. Greenfield projects: For greenfield pro- jects, companies should explore the poten- tial for partial or full electrification during the initial design phase. This involves devel- oping accurate energy models, simulating realistic operating scenarios, and evaluat- ing the reliability and availability of various electrification technologies. By address- ing these factors upfront, companies can optimise their designs for efficiency, lower emissions, and cost-effectiveness. Existing facilities: Retrofitting is a prac- tical path for existing sites. Today’s elec- trification technologies can replace up to 30-40% of energy needs in indus- trial plants, delivering significant gains in energy efficiency and emissions reduc- tion. Integrating renewable energy sources, either on-site or via utility partnerships, fur- ther amplifies the sustainability impact. Workforce development: Electrification demands new skill sets to empower the tran- sition. From system design to maintenance, the shift requires specialised expertise that is still in short supply. Schneider Electric is committed to closing this gap, training pro- fessionals globally to lead and support the electrified industries of tomorrow. Conclusion The energy transition presents a unique opportunity for the refining and petrochem- ical sectors to redefine operations for a cleaner, more resilient future. By embracing electrification and partnering with experts like Schneider Electric, companies can meet sustainability targets while enhancing performance, reliability, and profitability. Electrification is no longer a distant ambi- tion; it is a practical, powerful pathway to a green refinery. Prioritising electrification initiatives allows refineries to decarbon- ise operations, reduce CO₂ emissions, and unlock additional benefits such as:
did you know? Electrification presents a powerful opportunity for the refining and petrochemical industries to boost efficiency and cut emissions that electrified systems can operate seam- lessly, even during periods of low renewable output. Process electrification marks a para- digm shift – one that demands the collective expertise of the industry to succeed. The collaboration between process licensors and industrial technology leaders like Schneider Electric is already proving to be a powerful catalyst for progress.
Natural Gas: A Strategic Ally in the Electrification Journey
While electrification is key to a low-carbon future, natural gas remains a vital part of the energy transition. Often seen as a com- petitor to electrification, it can actually play a complementary role, bridging the gap between legacy systems and fully electrified operations. In compact environments, such as floating production storage and offloading (FPSO) units, electrification delivers efficiency gains by replacing multiple gas turbines with large electric motors. These systems improve control, reduce emissions, and enhance reli- ability. Yet, natural gas remains valuable, especially for on-site power generation in remote areas with limited grid access. By viewing natural gas as a strategic part- ner, not a rival, industries can unlock the full potential of electrification, balancing sus- tainability with operational resilience in a rapidly evolving energy landscape. Future Outlook As the refining and petrochemical sectors push toward net-zero goals, electrification
l Improved energy efficiency. l Lower maintenance costs. l Enhanced operational control.
l Greater flexibility through hybrid systems. l Integration with renewable energy sources.
Contact: damien.feral@se.com
To take a deeper dive into electrification, download the ebook Electrifying Refining and Petrochemical Industries
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