The focus was clear: to examine what’s ready, what works, and what should guide the sector forward.

Representing Kanthal, Dilip Chandrasekaran, Director of Business Development, took the stage to provide a practical update on electrification at key stages of steel production—real-world development, including test results, pilot-scale data, and an honest view of the challenges ahead.

“One of the main objectives was to present and discuss the technology readiness of various solutions,” says Chandrasekaran. “We were there to show where resistance heating already fits into the chain. It’s no longer about something that might work; it’s something we’re already scaling.”

Grounded technology in a policy-driven setting

The workshop was hosted by the Innovation Centre for Industrial Transformation and Emissions (INCITE), a body created to help accelerate the rollout of clean industrial technologies across Europe. But this wasn’t a demonstration event. The goal was to feed directly into the Sevilla Process, which underpins the EU Industrial Emissions Directive.

The room was full of people who would help define what is considered “best available”.

“If electric heating isn’t represented in standards and regulations, it won’t just be left out of the conversation; it’ll be left out of the policy. And if that happens, the opportunity to shift large parts of the sector is lost,” claims Nicolai Schaaf, Kanthal’s Sustainability Manager.

Where electric heating fits: Kanthal’s contribution

Chandrasekaran’s presentation focused on three key areas where Kanthal is developing or deploying electric heating technology: slab reheating, gas-based DRI processes, and ladle and tundish heating.

Slab reheating

One of the more emission-heavy stages of steel production, slab reheating is a clear candidate for electrification. Kanthal’s development efforts here focus on large-scale furnace systems, capable of reaching over 1,250°C (2,282°F), with power densities of up to 100 kW/m².

The technologies combine resistance and induction heating, using ceramic heating elements like silicon carbide (Kanthal’s Globar®) and molybdenum disilicide (Kanthal® Super), and are being validated through several active research programs:

• ELROS – A Swedish project (Vinnova) combining resistance and induction heating 
• E-Eco Downstream – A Horizon Europe project exploring hybrid setups with hydrogen burners 

“There was a lot of interest in electric reheating furnaces, especially from companies now looking more seriously at downstream emissions. That part of the process is gaining focus,” Chandrasekaran notes.

Electric gas heating for DRI

Kanthal’s electric gas heater portfolio is being developed for high-temperature applications such as direct reduced iron (DRI) systems and modified blast furnaces. These systems are designed to operate on natural gas and hydrogen mixtures, with modular and scalable formats for industrial integration.

A key milestone was reached at HYBRIT’s pilot plant in Sweden, where Kanthal’s direct heating technology was tested at 1.2 MW scale, achieving outlet temperatures of 950°C (1,742°F) with a thermal efficiency of 95%.

“Many companies are rethinking how to decarbonize blast furnaces, whether through modification or phase-out. Heating is central to that shift,” Chandrasekaran claims.

Although testing results have been promising, Chandrasekaran notes that challenges persist, particularly regarding temperature distribution and flow dynamics at scale.

Ladle and tundish heating

Kanthal, in collaboration with Ceba, has developed electric ladle preheating systems that are currently in operation and capable of handling ladles weighing up to 60 tons. These units can achieve refractory temperatures of 1,300°C (2,372°F) and effectively eliminate emissions of NOₓ and SOₓ associated with combustion.

The technology utilizes Kanthal’s ceramic heating elements and is being scaled up to accommodate larger ladle sizes, as customers seek to replace fossil-fuel-fired dryers in auxiliary operations.

A shift in conversation: from interest to implementation

What stood out at INCITE was the maturity of the dialogue. Most questions didn’t focus on whether electric heating works, but on how and when it can be integrated into existing processes.

“People wanted to talk timelines, energy input, integration complexity,” Chandrasekaran reflects. “That’s a different tone from even a couple of years ago. We’ve moved beyond explaining the concept; we’re now discussing what’s required to make it real.”

And that, perhaps, was the most important takeaway: electrification isn’t on the fringe of the steel conversation anymore. It’s in the room and in front of the people who decide what the next decade of decarbonization will look like.

Why being there mattered

For Kanthal, the goal was to establish electric heating as a viable solution.

“It’s important to be present at these workshops and show what’s possible, not just from a technology point of view, but a policy and permitting perspective,” Chandrasekaran adds. “We also must give a realistic picture of what it takes to scale. This is where that conversation starts.”

Schaaf agrees and points to the long-term impact of making that case early.

“INCITE will influence how industrial emissions are addressed in the next round of Best Available Techniques Reference Documents (BREFs),” he asserts. “If that process doesn’t reflect what electric heating can already do, we’re missing a critical lever in the transformation of the sector.”

Looking ahead

Kanthal will continue to engage in EU-level industry discussions, not only in the steel sector but also in industries such as glass, cement, and petrochemicals, where similar decarbonization challenges exist.

With multiple EU-funded projects underway, including pilot- and demo-scale validations, Kanthal remains dedicated to scaling what has already been proven and accelerating what still requires support.

This isn’t about presenting electric heating as a one-size-fits-all solution. It’s about making sure that where it fits, it’s recognized and regulated as a legitimate option.

“We’re not just building solutions, we’re building trust. And we’re making sure the people writing the rules understand what’s already possible,” Chandrasekaran concludes.