Electrification

One of the most important technologies to structurally reduce CO2 emissions is electrification. By partially or fully electrifying heat production, companies reduce their dependence on fossil fuels and prepare their production for a low-carbon future.

The Callens Group guides industrial companies through the electrification of their heat supply. Based on a thorough analysis, we determine which technology, or combination of technologies, best suits your production process, heat demand, and investment strategy. This allows us to deliver a solution that performs both technically and economically.

Discuss your electrification project

When is electrification a smart choice?

Electrification opens up new opportunities to organize industrial heat production more efficiently, more sustainably, and with the future in mind. Depending on the production process, it can help reduce CO2 emissions, improve energy efficiency, and lower dependence on fossil fuels. What’s more, electric technologies are evolving rapidly, making more and more applications technically and economically feasible today.

That is why the Callens Group does not start from a single technology, but from your entire energy system. We analyze where electrification creates the greatest added value and how it can be optimally combined with other technologies, such as heat recovery, combined heat and power, or the valorization of residual streams. The result is an integrated solution that suits your production process and your sustainability ambitions to perfection.

Industriele stoomketel elektrodeboiler
Cargill Haubourdin Eboiler 30 T Gasboiler 30 T 2

Why choose electrification?

  • To structurally reduce the CO2 emissions of your production process.
  • To reduce dependence on natural gas and other fossil fuels.
  • To partly avoid rising energy prices.
  • To move forward in the energy transition.
  • To make practical use of locally generated green electricity.
Your challengeBest-fit electrification technology
Making maximum use of waste heatIndustrial heat pump
Producing steam electricallyElectric steam boiler
Producing hot water or process heat electricallyE-boiler
Phased electrification without fully replacing existing systemsHybrid heat system
Reusing process vapor with minimal energy consumptionMechanical Vapor Recompression (MVR)
Combining multiple electrification technologies for maximum CO₂ reductionCustom solution

Which form of electrification is the best-fit solution?

Electrification can be implemented in several ways. The most suitable technology will depend on the required process temperatures, the desired capacity, the available energy sources, and the existing infrastructure. 

Some applications are especially well suited to industrial heat pumps, while, in other situations, electric steam boilers, e-boilers, hybrid systems, or Mechanical Vapor Recompression (MVR) are the better solution. 

That is why our specialists start from your specific production process. This allows them to find a solution that combines maximum CO2 reduction with energy efficiency, reliability, and a solid return on investment. 

BENEFITS

Benefits of
electrifying production processes

Electrification helps industrial companies make their heat production more sustainable, use energy more efficiently, and prepare for future challenges. Depending on the application, the right electrification technology can deliver both environmental and economic benefits.

Lower CO2 emissions

By partially or fully replacing fossil fuels with electric heat production, the CO2 emissions of your production process drop significantly.

Higher
energy efficiency

Electric technologies such as industrial heat pumps and MVR systems make maximum use of available energy and reduce overall energy consumption.

Less dependence on fossil fuels

Electrification reduces dependence on natural gas and other fossil energy sources and makes your energy supply more future-proof.

Smart use of local, green electricity

Electrification makes it possible to combine heat production with locally generated or sustainably purchased electricity.

Fully
customized

Every electrification solution is tailored to your heat demand, process temperatures, energy system, and investment objectives, so that technology, performance, and sustainability come together in the best possible way.

Phased energy transition

With hybrid solutions, the transition to electric heat can be implemented step by step, without putting the continuity of your production process at risk.

“Maximizing energy efficiency does not start with choosing a technology. It starts with mapping out your specific environment and goals.”

Production processes electrification projects

Callens Warmtepomp 3
Thermal technology Industrial Heat Pumps Electrification +1

Industrial heat pumps reduce CO₂ emissions

Capacity4.2 MW
Energy source100% electricity
Callens Vynova stoomketel waterstof 1
Thermal technology Hydrogen-fired Valorizing waste flows +2

Hydrogen fires 60 tons of sustainable steam per hour

Capacity2 x 30 ton/h
Design pressure16 barg
Fuelhydrogen, natural gas, combination
CO2-reduction10.000 ton/year
Beschikbare hoeveelheid H2> 1.200 kg/h
Eboiler 4
Thermal technology Electrode boilers Steam boilers +2

E-boilers combine increased production with lower CO₂ emissions

Capacity2 x 5 MW 
Connection voltage15 kV
FAQ

Questions?
We have the answers.

Electrification is especially worthwhile when heat production can be replaced by electric alternatives without compromising the continuity of the production process. Factors such as process temperature, energy consumption, available grid capacity, and the presence of waste heat determine which solution is best suited.
Discuss the possibilities with our specialists.

In many cases, a hybrid solution is the most efficient approach. Electric technologies then work hand in hand with existing heat installations, allowing the transition to a low-fossil energy supply to take place in phases.
Curious which hybrid solution suits your company? Our experts are happy to think along with you.

Electrification delivers the greatest added value when it is part of an integrated energy strategy. That is why the Callens Group always looks at how electrification can be combined with energy recovery, combined heat and power, or other CO2-reducing technologies.

Yes. the Callens Group executes industrial electrification projects from start to finish. We begin with an analysis of your energy system and production process, then select the most suitable electrification technologies. Our engineers then take care of the full engineering, delivery and installation of the systems, commissioning, and ongoing service and maintenance. This gives you a single point of contact throughout the entire project and ensures a solution that is fully aligned with your production environment from a technical, economic, and operational perspective.
More information about the different steps in our workflow is available here.

For a pharmaceutical company, the Callens Group fully electrified the steam supply for a new production line. The installation consists of two 5 MW electrode boilers, delivering a combined steam capacity of 15 tons per hour. Both e-boilers currently serve as backups for each other but, thanks to their sizing, they can also be operated simultaneously to support future production expansions. In addition to the e-boilers, the Callens Group also delivered the full balance of plant, including a feedwater tank, condensate vessel, thermal deaerator, high-pressure steam header, and the complete piping network. With an electrical efficiency of 99.9 %, a connection voltage of 15 kV, and an operating pressure of 8 barg, the company now has an extremely efficient, flexible, and future-ready steam supply with significantly lower CO2 emissions.
More information: https://www.callens.eu/en/electrode-boilers/eboilers-combine-higher-output-with-lower-co2-emissions

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