Introduction
Industrial electricity has been fundamental to technological advancement and economic growth, acting as a driving force in the transformation of modern societies. Since its inception, with the use of hydroelectric power and the development of generators and distribution networks, electricity has evolved to become an essential source of power in almost every industry.
The evolution of industrial electricity is a story of continuous innovation and progress. In this article we will discuss its origins, and how early sources of industrial electricity, from hydropower to the first thermal power plants, paved the way for the sophisticated electrical infrastructure that today supports industrial production on a global scale, highlighting the sources that drove the industrial revolution and shaped the world as we know it today.
History of electricity
Electric power generation has undergone an evolution marked by crucial innovations and contributions from various scientists over the centuries. One of the first significant breakthroughs was the demonstration of electrical conduction by Stephen Gray, whose work inspired the creation of glass friction generators in Leiden, Holland, in 1740.
This development was fundamental to the later experiments of Benjamin Franklin and the invention of the battery by Alessandro Volta in 1800, which established a continuous source of electric current.
In 1808, Humphry Davy developed the first electric arc lamp, an innovation that demonstrated the potential of electricity for lighting. Just twelve years later, in 1820, Hans Christian Ørsted discovered the relationship between electricity and magnetism, a finding that was essential for the development of electric motors and generators.
Michael Faraday and Joseph Henry, in 1831, confirmed that an electric current could be generated by the movement of a conductor in a magnetic field, laying the foundation for modern electric generators.
The 1830s also saw the invention of the rudimentary dynamo by Hippolyte Pixii, whose improvement by Antonio Pacinotti in 1860 enabled the continuous generation of direct current (DC).
In 1867, Werner von Siemens, Charles Wheatstone, and S.A. Varley independently developed the self-excited dynamoelectric generator, an innovation that ensured a more stable and efficient supply of electricity.
Zenobe Gramme perfected this design in 1870, facilitating its use to power motors and promoting wider adoption of electric power in a variety of industrial applications.
In the late 19th century, Charles F. Brush designed more reliable dynamos, while Thomas Edison invented the incandescent lamp in 1879, providing a more practical and safer source of illumination.
In 1882, Edison established the first central generating station on Pearl Street, New York, demonstrating the feasibility of large-scale electricity distribution and ushering in the era of urban electrification.
In parallel, Nikola Tesla developed alternating current (AC) systems that enabled the efficient transmission of electricity over long distances, overcoming the limitations of direct current and laying the foundations of modern power supply. His work facilitated the integration of different energy sources and the creation of more robust and flexible power grids.
Electricity, fundamental to modern civilization, is much more than a mere convenience: it represents a complex physical phenomenon that underpins the functioning of our increasingly technologized world. At its core, electricity manifests itself through electromagnetic interactions between charged particles, mainly electrons, within conductive materials.
This phenomenon, governed by Coulomb’s law and Maxwell’s equations, is exploited by various methods to power our infrastructure, drive industrial processes, and enable the information age.
Electricity generation
The flow of electrical charge, known as current and measured in amperes, is the lifeblood of electrical systems. This flow, whether in the form of direct current (DC) or alternating current (AC), is controlled and manipulated in precisely designed circuits to perform a wide range of functions.
From nano-scale operations within integrated circuits to vast electrical distribution networks spanning continents, the principles of electromagnetism are constantly being applied to achieve impressive engineering breakthroughs.
Understanding electricity requires an in-depth analysis of quantum mechanics, thermodynamics, and materials science. This involves exploring phenomena such as band theory in semiconductors, superconductivity at low temperatures, and the complexities of electronic mobility in different materials.
As we move forward in developing more efficient technologies for power generation and explore quantum computing, a solid understanding of electrical principles remains essential for innovation and progress in the field of electrical engineering.
The steam era and its limitations
The history of the steam engine is a fascinating journey through human ingenuity and perseverance. It is a tale that spans centuries, weaving together the threads of scientific curiosity, industrial necessity, and technological innovation.
Imagine, for a moment, the smoky depths of an ancient Greek workshop. There, in the flickering light of a lamp, a philosopher-engineer named Heron of Alexandria manufactures a curious device: a hollow sphere mounted on a stand, with bent tubes protruding from its center.
As he carefully pours water into the sphere and lights a fire under it, the assembled spectators gasp in amazement. Steam hisses out of the tubes and the sphere begins to spin, faster and faster. This is the Aeolipile, one of the earliest known steam devices, in the following image you can see this device, known as the first steam engine.
An Aeolipile is a machine consisting of an air chamber, usually a sphere, with curved tubes through which steam is expelled. The force resulting from this action causes the mechanism to start rotating, applying the law of action and reaction.
Fast forward almost two millennia. The world has changed dramatically. In the dank, dark tunnels of England’s coal mines, miners battle an implacable enemy: water. As they dig deeper in search of the black gold that fuels the nascent Industrial Revolution, they face a constant battle against flooding.
It is here, in these subway labyrinths, that the true potential of steam power begins to emerge.
Enter Thomas Savery, an enterprising engineer with a vision. In 1698, he introduces his “Miner’s Friend,” a steam-powered pump designed to extract water from mines. Savery’s invention is ingenious, but risky, explosion-prone and limited in scope. Nevertheless, it marks a crucial step forward, sparking the imagination of other inventors and engineers.
Among them is Thomas Newcomen, a blacksmith and Baptist lay preacher. Newcomen sees the potential in Savery’s work, but also its limitations. Over years of experimentation, he develops something truly revolutionary: the atmospheric engine.
Imagine a huge beam, balanced like a seesaw, with a piston at one end and a pump rod at the other. As the steam fills the cylinder and then condenses, the piston moves up and down, driving the pump with a rhythmic, almost hypnotic motion. It’s not just a machine; it’s a mechanical heartbeat, bringing the industrial world to life.
But the story does not end there. Over the following decades, a parade of brilliant minds contributed to the evolution of the steam engine. James Watt, with his independent condenser and rotary motion. Richard Trevithick, who dares to use high-pressure steam. George Stephenson, who puts steam engines on rails and changes transportation forever.
Each innovation builds on the one before it, each inventor stands on the shoulders of those who came before. The steam engine becomes more powerful, more efficient, and more versatile. It moves from the mines to the factories, from the factories to the railroads, from the railroads to the seas. It becomes the driving force of a transformation so profound that we still feel its effects today.
From the steam engine to the electric generator
An electric generator is a machine that transforms mechanical energy into electrical energy using the principle of electromagnetic induction discovered by Michael Faraday in 1831. Faraday observed that the relative motion between a magnet and a coil of wire generates an electric current in the coil.
This discovery led to the development of modern electromagnetic generators that use electromagnets instead of permanent magnets.
The majority of electricity generation in the United States and worldwide comes from plants that use turbines to drive electric generators. In this context, a turbine-driven generator transforms mechanical energy from the rotary motion of a rotor into electrical energy.
Steam turbines, which will account for approximately 42% of U.S. electricity generation in 2022, are the most widely used turbines in the world. In these turbines, steam is generated by burning a fuel in a boiler, whose heat is transferred to an exchanger to produce steam that then drives the turbine.
Industrial electrical systems
A typical electromagnetic generator consists of a stationary stator, consisting of insulated coils of wire arranged in a cylinder, and a central rotor carrying the electromagnet. As the rotor turns, an electric current is induced in each stator coil. These individual currents combine to form a single total electric current, which is the electricity generated and transmitted through power lines to customers.
- Combustion gas turbines: Very similar in operation to jet engines, they burn liquid or gaseous fuels to generate hot gases that drive turbine blades. Operate independently or in combination with steam turbines in combined cycle systems, where combustion gases from one turbine feed a second turbine to generate more electricity.
- In combined cycle systems: Generally, each turbine has its own generator, although there are also single-shaft configurations where both turbines drive a single generator. Combined cycle thermal power plants convert the thermal energy of natural gas into electricity through the combined operation of a gas turbine and a steam turbine.
- The process involves the operation of two consecutive cycles: the Brayton cycle, which corresponds to the conventional gas turbine, and the Rankine cycle, which operates with the steam turbine. Siemenes, with its new Siemens Flex-Plant™ combined cycle technology, has succeeded in providing clean, efficient, reliable, and highly efficient electricity.
The following video shows the operation of this innovative technology from Siemenes.
Siemens’ Flex-Plants - Flexible Combined cycle power generation.
- Combined heat and power plants (CHP): take advantage of waste heat not converted into electricity in steam turbines, combustion turbines, or internal combustion engine generators to generate additional heat for use in industrial processes.
Smart grids
With the arrival of the new millennium, the concept of smart grids has revolutionized the global energy landscape. These grids integrate the traditional elements of the electricity system generation, transmission, distribution, and marketing with advanced communication systems, creating a flexible and reliable environment.
The implementation of an SG requires the integration of various computer systems into the conventional power grid. This includes systems that store and analyze geographic and statistical information, monitor grid status, and control field equipment. In addition, smart meters and data management systems are needed to facilitate communication between meters and utilities, as well as real-time grid management.
One of the most significant challenges for SGs is their vulnerability to cyber-attacks. Because they are based on communication systems, they may be susceptible to sabotage, which could cause blackouts or other serious failures. However, the benefits are equally significant: greater integration of renewable energy, reduction of greenhouse gases, competitive pricing, and improvements in the quality and reliability of electric service, including the ability to self-repair faults and automate maintenance.
Generation of electricity from renewable sources
Hydroelectric turbines transform the kinetic energy of moving water into electrical energy by turning the blades of a turbine coupled to a generator. Similarly, pumped storage power plants, while employing similar hydroelectric turbines, function as energy storage systems, while hydrokinetic turbines are used in tidal and wave power generation.
Wind turbines, which harness the energy of the wind to move the blades of a rotor connected to a generator, are another important source of electricity. There are two main types of wind turbines: horizontal axis wind turbines, which are the most common, and vertical axis wind turbines.
How is artificial intelligence impacting industrial electricity efficiency?
The integration of artificial intelligence (AI) in the industrial field has led to a remarkable increase in energy efficiency, overcoming the limitations of traditional methods by introducing more advanced and adaptive systems.
This impact manifests itself in several key areas, where AI not only improves operational efficiency, but also optimizes predictive capabilities, adjusts energy consumption and supports sustainability goals in industrial operations.
Process optimization in industrial electricity
In an industrial environment, processes include multiple variables, such as motor speeds, pump flow rates, and temperature measurements, which must be constantly adjusted to maintain optimum efficiency.
Although operators possess experience and knowledge, they may not have the ability to identify complex patterns or insipient inefficiencies in these processes. AI systems, however, may be continuously analyzing operational data, learning from patterns, and making automatic adjustments to optimize all parameters.
This approach ensures that every aspect of the operation is running at peak energy efficiency, which not only reduces electricity consumption but also improves overall plant productivity.
Conclusions
The evolution of industrial electricity has contributed to the transformation of modern societies, enabling significant technological and economic advances. From its humble beginnings with hydropower to today’s complex power grids, this evolution has laid the foundation for the global industrial infrastructure that supports mass production and continuous development.
The history of industrial electricity is not only a testament to innovation but also a lesson in how energy sources, such as early thermal power plants, have shaped the modern world. Understanding this evolution is crucial to appreciating the importance of electricity in industry and its role in the technological future.
References
- https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8871889/
- https://www.clearesult.com/insights/how-ai-can-enhance-ee-in-commercial-industrial-facilities
- https://www.nature.com/articles/s41467-024-50088-4
- https://www.iea.org/commentaries/why-ai-and-energy-are-the-new-power-couple
- https://www.sciencedirect.com/science/article/abs/pii/S0301420723002155
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