Industrial Resistive heating

Resistive electric heating is a versatile, mature technology, ideal for low- to medium-temperature industrial heat and increasingly feasible into high-temp ranges. It allows near-100% heat efficiency, cutting combustion emissions entirely on-site. However, achieving ultra-high temperatures requires specialized materials and R&D. To scale for U.S. industrial decarbonization, investments are needed in supply chain expansion, component fabrication, and power infrastructure.

Resistive heating (aka Joule heating) occurs when electric current flows through a material that resists the current, producing heat (P = I²R) . Common systems include:

• Immersion heaters (liquids, oils, thermal fluids), circulation/inline heaters (process streams).
• Air duct or infrared heaters (drying, heating air).
• Electric furnaces and ovens for controlled-atmosphere or non-ferrous metal processing.
• High-temp elements (SiC, MoSi2, tungsten) for continuous heating up to 1,400–3,000 °C

Industrial Impact

• Ubiquitous presence: Replaces gas/oil burners in furnaces, kilns, boilers, ovens, dryers across metals, ceramics, chemicals, food, pharmaceuticals.
• Efficient & precise: Nearly 100% of electrical energy becomes usable heat; allows accurate temperature control .
• Process flexibility: Suitable for a wide spectrum—from low-temp drying to high-temp sintering and chemical reactors.

Emissions Impact

• CO2 benefits tied to grid mix: On clean or decarbonized grids, the emissions intensity is far lower than gas-fired systems. Typical grid emissions range from 10–358 kg CO2/MMBtu, compared to gas at ~117 kg/MMBtu.
• Up to 30% CO2 reduction: In metal, chemical, and cement plants using clean electricity and replacing fossil heat.
• 100% conversion efficiency of electrical energy to thermal energy—no in-facility combustion emissions.

Supply Chain & Bottlenecks

• Component specialization: High-temp heating elements (SiC, MoSi2, tungsten) and high-power control systems require precise manufacturing.
• Vendor concentration in U.S.: Most core expertise remains with a few legacy manufacturers; complex R&D required for ultra-high-temp solutions.
• Material availability: Critical to secure supply of refractory alloys and ceramics.
• Grid and infrastructure needs: High-power resistive heaters can stress facility power systems—upgrades to transformers and wiring may be needed.
• Recycling & reshoring: Limited U.S. machining and fabrication capacity for specialized high-temperature heater components prolongs lead times for reshoring.