Industrial process Electrification


Industrial electrification targets the world’s hardest-to-abate processes — those that currently depend on fossil-fired high-heat systems, emit large volumes of CO2, and represent major energy consumers. These sectors account for a disproportionate share of global industrial emissions, and shifting them to electrified processes (powered by renewables and microgrids) is essential for deep decarbonization. The table below ranks the most energy-intensive processes that are the primary focus for electrification technologies and pilots today.


Most Energy-Intensive Processes for Electrification

Rank Process Current Energy Source Electrification Pathway Notes
1 Primary Steelmaking (Blast Furnaces) Coke/coal Green hydrogen DRI + Electric Arc Furnaces Steel = ~7% of global CO2; pilots underway in EU/US/China
2 Cement & Lime Kilns Coal, petcoke, natural gas Electric plasma kilns, resistive heating, hybrid H2-electric systems High process heat + calcination emissions; pilots just emerging
3 Petrochemical Steam Cracking Natural gas-fired furnaces Electrified e-crackers using resistive/induction heating Largest emitter in chemicals; major pilots (BASF, SABIC, Linde)
4 Glass & Ceramics Furnaces Gas-fired continuous furnaces Hybrid electric-H2 furnaces, plasma torches, induction systems Continuous high-heat demand, strong pilots in EU
5 Polysilicon & Semiconductor Processing Electricity (already electrified, but very high loads) Efficiency improvements, renewable PPAs, microgrid integration Energy intensity drives ESG scrutiny; FBR tech reduces load
6 Non-Ferrous Metals (Copper, Aluminum, Nickel) Coal, gas (smelting); electricity (electrowinning) Electrowinning, electrorefining, electric arc furnaces Huge power users; direct tie to mining & battery supply chains
7 Pulp & Paper Drying Steam from gas/biomass boilers Electrified drying (heat pumps, microwave, resistive) Low- to mid-temp but very high aggregate demand worldwide

Together, these processes account for the majority of industrial emissions. Electrification strategies include direct electrified heating (induction, plasma, resistive), hydrogen substitution where electrification alone is insufficient, and integration with renewables, BESS, and microgrids to manage power demand. Progress in these hard-to-abate sectors will define the pace of industrial decarbonization over the next two decades.

Electric Equipment

High-Temperature Heat (>500°C)

Medium-Temperature Heat (100–500°C)

Low-temperature Heat (<100°C)

Electrochemical Conversion


Major Sectors & Processes

Here's a list showing major industrial sectors, key processes, and the equipment/technology stack involved.

Mining & Mineral Processing


Refining & Smelting


Advanced Manufacturing


Traditional High-Temp Industries


Recycling & Circularity


Green hydrogen


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