Let’s explore the top five sectors leading the way in industrial electrification.

1. Steel and other metals 

Roller hearth furnaces, continuous annealing lines (CAL), and continuous galvanizing lines (CGL) are examples of downstream processes that can be electrified using resistive heating technology, but the list can be extended to practically any heating process.

Dilip Chandrasekaran, Business Development Manager, Kanthal.Steel production is one of the most carbon-intensive industrial processes, accounting for a significant share of global greenhouse gas emissions. Traditionally, steelmaking has relied on coal-powered blast furnaces to generate the intense heat required to convert iron ore into steel. However, with the shift toward electrification, the steel industry is embracing new technologies that drastically reduce emissions. 

A key player in this shift is the Electric Arc Furnace (EAF), which melts scrap using electricity rather than coal. EAFs, particularly when powered by renewable energy sources, can reduce emissions by up to 75%.

Roller hearth furnaces, continuous annealing lines (CAL), and continuous galvanizing lines (CGL) are examples of downstream processes that can be electrified using resistive heating technology, but the list can be extended to practically any heating process.

Dilip Chandrasekaran, Kanthal Business Development Manager, asserts, "Many steel companies are not aware that electric heating can achieve the required temperature or effect, but our elements are powerful enough but also improve thermal efficiency and the work environment while contributing to quality improvements." He adds, "Once a steel company is willing to switch to electric, we can help with the rest."

An emerging focus in this electrification journey is Direct Reduced Iron (DRI) technology. Currently, most DRI plants operate using natural gas, but electrification could reduce emissions by up to 30%. In the future, fully electric hydrogen DRI plants could achieve complete emission-free operation, reinforcing steel's potential as a truly sustainable material

With electrified steelmaking gaining momentum, the industry is poised to make significant strides toward decarbonization, positioning steel as a sustainable material for the future.

2. Cement, lime and pulp  

Jesper Ejenstam, Vice President and Head of R&D, Kanthal.The cement, lime, and pulp industries, responsible for approximately 8% of global CO2 emissions, are now exploring and adopting electrification solutions, such as electric kilns and plasma technologies. Cement production, for instance, demands extremely high temperatures, traditionally achieved through coal or natural gas.

To address this challenge, the €20 million ELECTRA project, co-funded by the EU's Horizon Europe program, is a pioneering initiative driving sustainability in these heavy industries. With 17 partners from eight countries, the project aims to revolutionize the cement, lime, and pulp sectors by developing scalable, modular, electricity-based technologies.

"The cement, lime, and pulp industries have a significant carbon footprint, primarily due to the calcination process, where calcium carbonate is heated to over 1,000°C (1,832°F) to produce lime," explains Jesper Ejenstam, Vice President and Head of R&D at Kanthal. This process not only requires vast amounts of energy—typically from fossil fuels—but also leads to considerable CO2 emissions.

Kanthal's innovations, which plan to replace traditional combustion with electric heating, are addressing both direct emissions from fuel combustion and indirect emissions from the calcination process. These advancements will be crucial for reducing the environmental impact of the construction sector, which remains vital for global infrastructure development.

3. Aluminum

Ole Stadum, Sales Area Manager, Kanthal.Aluminum production is crucial across industries like automotive and aerospace but remains highly energy-intensive and traditionally reliant on fossil fuels. The primary processes demand significant heat and power, generating substantial carbon emissions. Innovative inert anode technology could reduce CO₂ emissions in smelting by emitting oxygen rather than carbon. “If inert anode technology can be perfected, it will mean CO₂ emissions in the reduction process will be almost zero, and that will be a revolution,” says Ole Stadum, Sales Area Manager, Kanthal.

While the reduction process remains challenging for emissions, downstream improvements offer significant gains. “We are seeing many aluminum plants moving toward greater sustainability, and since there is not much that can be achieved in the reduction area, they are aiming to reduce emissions as much as possible in other production steps downstream,” Stadum adds. Electric heating technology not only lowers CO₂ emissions but also enhances efficiency, supporting sustainability goals.

Electrifying aluminum production aligns with the industry’s carbon reduction targets and contributes to the shift toward lightweight, durable materials essential for electric vehicles and renewable energy infrastructure.

4. Mining Industry 

Mining is a critical industry for the global supply chain, providing the raw materials needed for everything from construction to renewable energy technologies. However, mining is also a major source of carbon emissions, particularly from the equipment used for drilling, hauling, and processing ore.

To address this, the mining industry is increasingly turning to electrification. Battery-electric mining vehicles and equipment are being deployed in underground and surface operations, significantly reducing emissions and improving operational efficiency. Major players are leading the charge by investing in electric-powered mining fleets and electrified mineral processing technologies like electrowinning, which uses electricity to extract metals like copper and nickel from ore.

Additionally, refining processes, which traditionally rely on combustion, could also transition to electrification using Kanthal heating technology, presenting another avenue for substantial emission reductions in the industry.

The electrification of mining is essential not only for reducing the industry's carbon footprint but also for meeting the rising demand for materials like lithium, cobalt, and nickel, which are crucial for electrification technologies such as batteries and renewable energy systems.

5. Lithium-ion battery manufacturing 

Sachin Pimpalnerkar, Global Product Manager at Kanthal.At the forefront of the electrification movement is the lithium-ion battery industry, which powers electric vehicles, renewable energy storage systems, and a vast array of consumer electronics. As the demand for electrified transport and grid storage surges, lithium-ion battery production is scaling rapidly.

However, manufacturing these batteries is highly energy-intensive, particularly during the electrode production and cell assembly phases. The creation of cathode materials, for example, requires calcination at temperatures between 800°C and 1,000°C (1,472°F to 1,832°F). Achieving and maintaining exceptionally high purity levels in the cathode materials is critical, making precise temperature control essential. Like other industrial high-temperature processes, furnace operators face the challenge of optimizing energy efficiency and productivity while consistently delivering high-quality cathode materials.

"Kanthal's heating systems provide precise temperature control in the zones where it’s needed, ensuring optimal quality for cathode powder with improved energy efficiency and productivity," explains Sachin Pimpalnerkar, Global Product Manager at Kanthal.

Moreover, the refining of spodumene, currently performed with combustion, could also transition to electrification, further reducing emissions in lithium processing.

As electrification continues to gain traction, these industries will play a pivotal role in shaping the next generation of industrial practices, ensuring that sustainability and technological innovation go hand in hand.