Electrification of operational processes has gradually become a global trend as the cost of renewable electricity and electrical equipment continues to decline. This process aids industrial enterprises in saving money and minimizing their greenhouse gas emissions. Industrial electrification also integrates electricity and various industry sectors by substituting fossil energy consumption with electrical ones. This results in the incorporation of renewable energy and the conversion of difficult-to-control power sectors.
Since 1989, Clairon Metals Corporation has broadened and developed as a provider of metal components to various industries and sectors. We are able to service many different sectors including electrification and continue to provide the reliability and quality that our customers have become accustomed to.
What Is Electrification?
Electrification replaces systems that use fossil fuels — natural gasses, oils, and coals — with technologies utilizing electricity as the primary energy source. It can also reduce carbon dioxide emissions from various sectors, depending on the materials or resources used to generate power. These include transportation, building, agricultural, forestry, and other industrial processes.
In industrial processes, electrification involves modifying procedures — such as melting, separating, and refining — with electric methods, such as electric arc furnaces and resistance heating.
Here are some examples of electrification in industrial processes:
Vehicle Electrification
Vehicle electrification fuels a vehicle with electricity, replacing its traditional energy power sources with electric-powered components. Generally, it focuses on the electric powertrain and its ancillary systems, including onboard and off-board charging systems and wireless power conversion.
The primary determinants for vehicle electrification are creating new intelligent transport systems, mitigating pollutants, and reducing fossil fuels.
Building Electrification
Also referred to as beneficial electrification or building decarbonization, building electrification replaces electricity for fossil fuels — such as oil, gas, and coal — for residential and commercial applications. The objective is carbon-neutral, all-electric infrastructures fueled by the sun, wind, and other renewable energy sources. These electrification approaches work as a decarbonization tactic since the electricity consumed is generated from clean resources.
Agricultural Electrification
Agricultural electrification, often known as fuel switching, is the procedure that enables farmers to rely less on alternative energy sources to improve their processes and reduce carbon emissions. This also helps agricultural producers to automate their tasks and streamline operations for increased efficiency.
Benefits of Industrial Electrification
Each industry and its particular processes has a distinct path to capitalizing on the possibilities of clean electrification. For example, some sectors — like mining and forestry — attempt to electrify off-road mobility, utilizing the acquired knowledge from on-road transportation. However, it needs to modify vehicles and charging infrastructure based on site-specific requirements.
The electrification of the fuel used by enterprises for energy has significant advantages. In general, electrically driven technology is slightly more energy efficient than the conventional alternative but has reduced maintenance expenses. Industrial boilers and heat pumps also require a cheaper investment cost. Lastly, the industrial site’s greenhouse gas emissions are greatly reduced if carbon-free electricity is utilized.
Existing and Emerging Electrification Technologies
The electrification of industry demands considering several existing and upcoming processes and technologies. Here are some examples of electrification technologies that have emerged over the years:
Solar Photovoltaic Systems
Solar photovoltaic systems are a widely used technology for generating renewable energy. They are composed of one or more solar panels, an inverter, and other hardware that convert solar energy into electricity. They are in high demand in places and regions with abundant solar radiation.
Electric-Vehicle Charging Infrastructure (EVCI)
Also referred to as a charge point, EVCI is a piece of equipment that provides electrical power for charging plug-in electric vehicles. This technology permits vehicle electrification for increased mobility and the transition from internal combustion engines. However, it requires an extensive network for quick and convenient charging.
Battery Energy Storage Systems (BESS)
Also known simply as battery storage, BESS are systems that enable energy from renewable sources — such as solar and wind — to be preserved and supplied when people require power the most. These systems have significant residential, commercial, industrial, and utility-scale applications due to the need for increased grid flexibility.
We provide the following services for your next electrification project.
Resistance Welding
Resistance welding is a common manufacturing technique that enables manufacturers to instantly forge a solid connection between two or more metal components. This adaptable method delivers reliable and accurate welds while enhancing operational productivity and minimizing the risks of distortion.
This welding technique connects metal sheets or components using force and the heat generated by the resistance of the welding current flow. By providing precise pressure to a workpiece during the welding process, resistance welding technology sends electrical currents through electrodes functioning as conductors for a set period.
Resistance welding encompasses a variety of processes that utilize electrodes of varied dimensions or conductor types. Two of the most common approaches are spot welding and projection welding.
Spot Welding
Spot welding is an electric resistance technique that uses heat and force to make welds. First, applying an electric current from two tips on either side of the components causes the metal to melt and produce a weld pool. Then, as this pool cools, it fuses the two distinct metal pieces.
As the metals are fused utilizing significant quantities of energy in a short time (about 10 to 100 milliseconds), the area surrounding the weld pool is unaffected by the extreme heat. This results in a limited heat-affected zone and a clean weld.
The advantages of this welding technique are as follows:
- One of the fastest and cleanest welding methods
- Straightforward process
- Has no open flame present
- Allows automation through welding robots
- Permits simultaneous welding of multiple metal sheets
- Does not consume filler materials
- Cost-effective
Projection Welding
As with spot welding, projection welding generates force and heat through resistance to the flow of the welding current. The only distinction is that this technique utilizes a weld nut with meltable projections. These weld points are usually metal protrusions that generate heat at the place of contact to isolate the weld. As heat is applied, the protrusion collapses to produce a weld nugget, which eventually solidifies as a weld.
Here are some of the benefits that projection welding offers:
- Allows for more than one weld to be completed at the same time
- Requires lesser heat and pressure than spot welding
- Easy to adjust to different parameters
- Reduces surface imperfections
- Has smoother finish
Industries We Serve
At Clairon Metals Corporation, we strive to meet the electrification requirements of various industries. As these sectors begin transitioning to the use of electrification outputs we are here to serve. The following are some of the sectors that we are currently serving that are offering electric models:
Recreational Vehicle
RVs equipped with modern electrification systems can provide a more comfortable environment with features like air conditioning, lighting, and appliances that run on electricity. Electrification can also offer a more convenient and easier way to power various devices and appliances. This eliminates the need for generator use and the associated noise and maintenance.
Lawn and Garden
Electrification in lawn and garden allows for using more efficient and effective equipment, such as electric lawnmowers, hedge trimmers, and leaf blowers. These tools and machinery can greatly increase productivity and reduce the time and effort required for landscaping tasks.
Agriculture
Agricultural electrification increases productivity by providing power for irrigation systems, precision agriculture equipment, and other farm machinery. This results in reduced time and labor required for tasks and improved efficiency. Electrification can also enhance the quality of crops by providing a consistent and controlled energy supply for temperature and lighting systems in greenhouses and agriculture facilities.
Electric Vehicle Charging
Electrification in EV charging allows for a convenient way to recharge electric vehicles, reducing gasoline dependence and increasing EVs’ overall usability. Moreover, with the widespread availability of fast and efficient charging infrastructure, EVs can have longer ranges and be more practical for daily use.
Heat Pumps
Heat pumps use electricity to transfer heat from one location to another, making them a highly efficient heating and cooling source. This can result in significant energy savings compared to traditional heating and cooling systems.
Solar Systems
Solar systems use electricity generated from the sun to produce power, making them a clean and renewable source of energy. This can help to reduce the dependence on fossil fuels and improve the sustainability of energy production. Furthermore, solar products can provide cost savings compared to traditional energy sources over the long term.
Battery Storage
Battery storage systems can store excess energy generated from renewable sources, such as solar and wind, making the power supply more reliable and consistent. This can help reduce intermittency’s impact on renewable energy sources and ensure a stable power supply.
Clairon Metals’ Efforts Toward Electrification
Clairon Metals Corporation has decades of experience creating metal components for sectors ranging from recreational vehicles, automotive and transportation to HVAC and solar. We also provide various on-site services and capabilities to expedite the production of high-quality products while reducing expenses.
Partner With Clairon Metals for Quality Services and Capabilities
Clairon Metals Corporation provides extensive tooling and fixture design, welding, and metal stamping services! We also offer complete secondary processes, which include machining, drilling, multi-spindle tapping, reaming, and assembling. Moreover, we are equipped with cutting-edge machinery, and our in-house tooling department enables us to provide customized, high-quality customer service.
Contact us immediately for further details! You may also request a quote, and we will get in touch with you as soon as possible.