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Why industrial heating must go electric
Industrial heating is fundamental to manufacturing. Despite the necessity, it remains one of the largest contributors to carbon emissions and a massively overlooked area of decarbonization. For over a century, industries have relied on coal, oil, and natural gas to fuel the heating processes. This over-dependence has led to high energy costs, unpredictable fuel supplies, environmental degradation, and increasing regulatory pressure.
By Tanya Rudra, Editor, Kanthal
To address the aforementioned 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. www. heat-exchanger-world. com Heat Exchanger World April 2025
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