Dilip Chandrasekaran, Senior Vice President and Director of Business Development, Kanthal.To address these challenges and leverage the rapid expansion of renewable energy, manufacturers are increasingly transitioning to electrification. Simultaneously, the rise of IoT, automation, and AI-driven process control has metamorphosed how industries operate. Replacing gas with electric heat now encapsulates integrating smart systems, improving efficiency, eliminating emissions, and future-proofing operations.

Kanthal has pioneered electric heating technology for over 90 years, but its relevance has never been greater. It has successfully shifted the conversation from whether electrification is possible to how quickly it can be scaled. With a diverse portfolio of materials, including metallic (NiCr, FeCrAl) and ceramic (SiC, MoSi2), alongside deep expertise in industrial applications, pilot-scale testing, and modeling, Kanthal continues to advance electrification.

"Most steel companies are aware that electric heating elements are not only powerful enough but also improve thermal efficiency and the work environment while contributing to quality improvements," says Dilip Chandrasekaran, Senior Vice President and Director of Business Development at Kanthal. "Once a steel company is willing to switch to electric, we can help with the rest."

The business case for electrification

While sustainability is a major driver of industrial heating electrification, it also makes a solid business case.

Electric heating outperforms fossil-based systems in several key areas:  

• Up to 90 percent efficiency – Fossil-fired heating systems lose energy through combustion, while electric heating delivers heat directly where needed.  
• Precise temperature control – Electric heating maintains stability within one degree Celsius, improving process control and product consistency.  
• Lower operating costs – With no combustion residues, electric heating systems experience less wear and tear, reducing maintenance and downtime.  
• Eliminating NOx and SOx emissions – Electrification improves workplace safety and air quality while ensuring compliance with tightening emissions regulations.  
• Seamless integration with digitalization – Electric heating enables better automation and process optimization through IoT and AI-driven control systems.  

"You can retrofit an existing furnace simply by replacing the gas burners with tubes and electric heating elements and making a few small modifications," explains Chandrasekaran. "That alone improves efficiency, process stability, and the work environment."

Industries already electrifying

Efficiency gains, peak performance, energy security concerns, and even regulatory mandates are already propelling industries relying on high-temperature processes to phase out fossil fuels. Even for one of the hardest-to-abate sectors, steel, Kanthal has identified three heating processes in downstream production ready for electrification – the Continuous Annealing Line (CAL), Continuous Galvanizing Line (CGL), and Roller Hearth Furnaces.

Through decades of working with industrial heating solutions, Kanthal has developed a broad portfolio fit for applications depending on the temperature requirements and atmospheric conditions across key industries like lithium-ion, glass, aluminum, ceramics, and semiconductors among others. Kanthal can also customize its products and designs to suit specific requirements.

Prothal®: Enabling electrification in heavy industries

Kanthal's process gas heater, Prothal®.One of the biggest challenges in industrial electrification has been high-temperature gas heating, a crucial process in steel, petrochemicals, cement, and other heavy industries.  Kanthal’s Prothal® electric process gas heater was developed to solve this problem, offering a high-efficiency alternative to fossil-fired gas heaters.

Originally tested for HYBRIT (Hydrogen Breakthrough Ironmaking Technology), a joint initiative by SSAB, LKAB, and Vattenfall, Prothal® proved that electric heating could support hydrogen-based DRI process by delivering precise, high-temperature process gas heating at scale.

The same technology is being/could be adapted for a range of heavy industries.

The Prothal® portfolio, under development, has the potential to deliver outlet temperatures up to 1,100°C (2,012°F) and operate efficiently across gas compositions, including 100 percent hydrogen, hydrogen-nitrogen blends, and air. Other technologies are currently under development that can reach even higher temperatures for example the ELECTRA project requires systems that can reach over 1,200°C (2,192°F).

The ELECTRA project, with a budget of €20 million, partly funded by the EU's Horizon Europe program, is a groundbreaking initiative to drive sustainability in the cement, lime, and pulp industries. By uniting 17 partners from eight countries, the project is poised to transform these sectors through advanced, electricity-based technologies that are scalable and modular.

"All over the world, governments are requiring companies to move away from fossil fuels, and most major steelmakers are looking for ways to reduce their emissions," says Chandrasekaran. "Only they can make the decision, but once they do, we have the expertise and experience to make the switch to electric happen."

Challenges of electrification and how to overcome them

Despite the clear advantages, large-scale industrial electrification requires careful planning.

1. Power supply and infrastructure 

The availability of enough electrical capacity and the infrastructure to support it continue to be the biggest roadblocks that prevent the rapid adoption of industrial electrification. Moreover, electric heating can fully eliminate CO2 emissions, however, for this to happen, access to fossil-free electricity is a must.

According to the International Energy Agency, by 2030, renewables are expected to approach a 50% share of the global electricity mix, up from around 30% today. Heat pumps and other electric heating systems will be outselling fossil fuel boilers globally, and investments in new offshore wind projects will be three times higher than those in new coal and gas-fired power plants.

2. Efficiency calculations  

Chandrasekaran notes that while thermal engineering calculations can compare the efficiency of electric solutions to gas-fired systems, accuracy remains a concern. “Steel companies tend to have limited knowledge of the impact that changes in heat transfer and efficiency may have on the properties of their end product,” he adds.

This is why stepwise conversion, pilot-scale testing, and modeling are crucial in electrification for specific processes.

3. What to electrify? 

Chandrasekaran explains that identifying suitable processes for conversion is a major obstacle in electrifying steel production. While certain processes may lend themselves easily to electrification, others, present unique complexities due to temperature requirements and operating conditions.

4. Process adaptation and control systems

Electric heating requires a different approach to temperature regulation compared to gas-fired systems. Unlike gas burners, which distribute heat unevenly, electric heating enables precise control over temperature zones.

"With a gas furnace, the control system can be quite simple," Chandrasekaran explains. "But running an electrical solution could be more complex. You need to understand how to control and regulate the power of the elements to avoid overheating and maximize the lifetime of the elements. However, the upside is that the temperature control in the furnace will be significantly more accurate when using electric heating."

5. Scaling up for full commercialization

Many companies recognize the benefits of electrification but struggle to scale beyond pilot projects. This is where Kanthal becomes the difference between hesitation and transformation. With deep technical expertise, advanced simulation capabilities, and industrial-scale testing, Kanthal helps manufacturers bridge the gap between concept and reality.

Prothal® and other electric heating solutions are moving into full-scale industrial deployment. Kanthal ensures that industries do not just test electrification, but successfully integrate and scale it across their operations, making the transition as seamless and efficient as possible.

A defining moment for industrial heating

Industries worldwide recognize that electrification is essential for meeting their sustainability targets while enhancing efficiency. The companies that make this shift today will shape the future of industrial heating.

As regulatory pressure intensifies and energy markets grow more volatile, industries are caught between rising costs and the urgent need to decarbonize. In this shifting landscape, electrification is the logical next step to securing long-term competitiveness, efficiency, and stability.

"Industries worldwide recognize that electrification is essential for meeting their sustainability targets while enhancing efficiency. The companies that make this shift today will shape the future of industrial heating, says Chandrasekaran."

With 90 years of expertise in electric heating materials, components, and systems, Kanthal provides industries with the solutions they need to electrify their heating processes.

The future of industrial heating is electric. The companies that act now will lead the way.