Process heat is essential for industrial production. From drying and chemical reactions to food processing, material treatment and manufacturing, numerous industrial processes depend on a reliable supply of thermal energy.
The required temperatures, heating capacities and heat transfer methods vary significantly depending on the application.
Selecting the right industrial process heating solution is therefore essential for efficient production, reliable operation and the long-term economic performance of a manufacturing facility.
AURA develops and manufactures customized process heating systems for industrial applications. Our expertise covers electric and fired heat generation, thermal oil systems, steam generation, heat transfer and industrial waste heat recovery.
We support companies in designing new process heating systems, improving existing installations and developing efficient solutions for their specific thermal requirements.
Process heat is heat that is required in industry for technical processes. These processes include, for example, the drying of components, the melting of metals or the provision of steam. At the same time, the term process heat is also used to describe the waste heat of thermal processes in industry. For example, waste heat from power plant processes can be fed into local and district heating networks and used to heat buildings.
The decisive parameter for determining process heat is the temperature level. Thermal processes in industry each require a certain, process-specific temperature level. The higher the temperature level, the greater the energy input required to generate the heat. The energy consumption of companies therefore depends to a large extent on the temperature level of the process heat.
In European industry, these temperature levels are predominant:
In industry and commerce, heat is required in a wide variety of forms to change material or workpiece properties. Some typical thermal processes are:
Industrial process heat can be generated using different energy sources and heating technologies.
As an experienced process heat specialist, AURA develops highly efficient solutions for industry. Our innovative process heat systems are used across industries and range from efficient thermal oil heating systems and indirect steam generators to hot water systems, water bath heaters and edible oil heating systems.
Our innovative products are used in numerous industries, from mechanical and system engineering to energy technology, the chemical industry, the food industry, the oil and gas sector, and the timber industry.
Electric heating systems convert electrical energy directly into thermal energy.
They provide precise heating control without a combustion process at the installation site.
Electric process heat can be particularly attractive when direct combustion emissions are to be reduced or renewable electricity is available.
Fired heating systems generate thermal energy through the controlled combustion of suitable gaseous or liquid fuels.
They are particularly relevant for industrial applications requiring high thermal output and continuous heat supply.
Many industrial processes generate exhaust gases or other waste heat streams that still contain useful thermal energy.
Waste heat recovery systems transfer this energy to suitable heat consumers, reducing the need for additional heat generation where the recovered energy replaces purchased energy.
Industrial processes do not always require the same heat transfer medium.
Heat exchangers can transfer thermal energy between thermal oil, steam and water circuits.
This allows existing heat sources to supply different industrial processes. See AURA heat transfer solutions.
Different energy sources are used for the production of process heat. The predominant energy source for process heat generation in industry is still fossil fuels such as natural gas or heating oil. However, the combustion of fossil fuels releases considerable amounts of climate-damaging greenhouse gases such as CO2.
Innovative system technology allows an increase in the efficiency of the generation process:
Efficient heat generators and suitable control systems can reduce unnecessary energy consumption.
Thermal energy from exhaust gases or other process streams can be recovered and reused where suitable heat consumers are available.
Accurate temperature control helps ensure that thermal energy is supplied according to the actual process requirements.
Suitable insulation, optimized operating conditions and efficient heat distribution can help reduce avoidable losses.
Existing process heating systems can often be improved through targeted modifications rather than complete replacement.
Replacing or supplementing fired heat generation with electric heating can reduce direct combustion emissions and support industrial decarbonization.
The most suitable measures depend on the technical and economic conditions of the individual process.
The energy consumption of companies is largely determined by the demand for process heat. For this reason, process heat also has a significant impact on companies’ operating costs. Reducing energy consumption for process heat generation is therefore in the economic interest of companies. At the same time, legislators are imposing increasingly stringent requirements on energy efficiency and setting financial incentives to reduce CO2 emissions.
For energy-intensive companies in industry and commerce, investing in more efficient process heat generation and utilization usually pays off quickly. Measures such as investing in modern boilers, integrating renewable energy sources, or extracting waste heat for reuse not only protect the company’s liquidity, but also the environment.
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