At the heart of this transformative effort is Kanthal, a global leader in electric industrial heating technology. Jesper Ejenstam, Vice President and Head of R&D at Kanthal, sheds light on the company's pivotal role in the project, which centers on developing high-temperature electric heating solutions to replace fossil-fuel-dependent processes.

A new approach to industrial heating

By replacing traditional combustion methods with electric heating, Kanthal is enabling the addressing of both direct emissions from fuel combustion and indirect emissions from the calcination process itself.

Jesper Ejenstam, Vice President and Head of R&D, Kanthal."Kanthal's participation in the ELECTRA project is essential," Ejenstam emphasizes. He explains, "The cement, lime, and pulp industries are notorious for their significant carbon footprints, mainly due to the calcination process, where calcium carbonate is heated to temperatures around or over 1,000°C (1,832°F) to produce lime."

This process not only consumes large amounts of energy, typically derived from fossil fuels but also results in the release of substantial CO2 emissions.

By replacing traditional combustion methods with electric heating, Kanthal is enabling the addressing of both direct emissions from fuel combustion and indirect emissions from the calcination process itself.

Meeting the technical challenges

While the project goals are clear, overcoming them is riddled with technical challenges. "Today, no one really knows how to make an industrial-scale fossil-free cement plant," Ejenstam quips. "One of the most significant hurdles is developing systems that can heat materials or process gases to the necessary temperatures without relying on fossil fuels. Kanthal's current technology can heat gases to around 1,100°C (2,012°F), but the ELECTRA project requires systems that can reach over 1,200°C (2,192°F)," Ejenstam says.

"We need to innovate with new materials and systems," Ejenstam stresses. "For instance, we are exploring the use of ceramic elements for gas heating systems, something we've never done before." This innovation is not just about achieving the required temperatures; it also involves ensuring that the systems are durable, efficient, and capable of being scaled up for industrial use.

Addressing CO2 emissions

In addition to making the calcination process fossil-free, the consortium is also developing solutions for managing the CO2 produced during the process. "Two key factors contribute to the CO2 intensity of this process," Ejenstam explains. "First, the use of fossil fuels in heating, and second, the release of CO2 as a byproduct of the materials themselves." While the primary focus of the ELECTRA project is on replacing fossil fuels with electricity, it also addresses the challenge of managing the CO2 emissions that are inherent to the materials being processed.

Strategic alignment with sustainability goals

Kanthal's participation in the ELECTRA project is not just about developing new technologies; it also aligns with the company's broader strategic goals. Ejenstam highlights that the cement, lime, and pulp industries are significant global emitters of CO2, and by helping to make these industries more sustainable, Kanthal is contributing to the fight against climate change. "This project is very much in line with Kanthal's purpose to make life better for people and the planet," he says. "If we can be part of enabling this transformation, it opens up new possibilities—not just for us, but for the entire industry."

The project also presents a significant business opportunity for Kanthal. The demand for fossil-free heating solutions is expected to grow as industries seek to reduce their carbon footprints, and Kanthal is well-positioned to meet this demand with its innovative technologies. "We see this as an opportunity to increase demand for our products in these applications," Ejenstam notes.

Collaboration and innovation

One of the key strengths of the ELECTRA project is the collaboration between the 17 partners. This diverse group brings together expertise from across the entire value chain, including basic and applied research, technology providers, end users, and business creators. Ejenstam emphasizes the importance of this collaboration in developing solutions that are not only technologically advanced but also practical and scalable.

"We are working closely with our partners to design and test prototypes which will be followed by demonstrating," he explains. "This is an exploratory project, so there is a lot of back and forth as we figure out how to solve the challenges we face." The collaborative nature of the project ensures that the solutions developed will meet the needs of all stakeholders, from plant manufacturers to end users, and that they will be capable of being scaled up for industrial use.

Looking to the future

The ELECTRA project, launched with a key meeting in January 2024, is set to transform industrial standards over its four-year span. Kanthal’s innovative technologies aim to reduce CO2 emissions in the cement and lime industries by over 90%, signaling a monumental step toward a sustainable future. This ambitious project not only promises to slash emissions but also to speed up the shift to electrification in these sectors. The collaborative nature of ELECTRA embodies a future where innovation and environmental responsibility drive industrial progress.