Peter Dömstedt, Project Manager, Kanthal.Electrification is well underway across industrial heating processes, and Kanthal has been and continues to be a key enabler of this shift. However, electrifying the process gas heating comes with its own unique set of challenges. At Green Steel World 2025 in Düsseldorf, Germany, Peter Dömstedt, Project Manager, Kanthal, presented how the company is addressing this head-on. With the Prothal® portfolio of electric process gas heaters, Kanthal is expanding the scope of possibilities. This technology, soon to be commercialized, is a scalable, high-efficiency solution for one of the industry’s most demanding applications.

The problem with fossil-fired process gas heating

Gas heating has remained a blind spot in electrification for a reason. It's one of the most technically demanding thermal applications in heavy industry. Fossil-fired heaters have been able to meet the necessary temperatures, but they come with significant downsides:

• Combustion-related inefficiencies – Thermal energy is lost through flue gases and heat dissipation. 
• CO₂, NO_x, and SO_x emissions – A major hurdle in industries under pressure to meet emissions targets. 
• Poor temperature control – Combustion is inherently harder to regulate precisely, leading to process instability. 
• Maintenance issues – Combustion residues create wear and fouling in the system. 
• Safety and noise concerns – Especially in enclosed industrial settings. 

A high-stakes opportunity: DRI

In a major development, Kanthal and Danieli are preparing to supply the first electric process gas heater for commercial use in a DRI application.

Steelmakers are under mounting pressure to reduce emissions, and hydrogen-based DRI is emerging as one of the most promising technologies to replace blast furnaces. However, DRI processes depend on precisely heated gas delivered under pressure and at high temperatures. Without a clean, controllable way to heat that gas, the process remains stuck in a fossil fuel loop.

Kanthal stepped into this gap. As part of the HYBRIT initiative, a collaboration between SSAB, LKAB, and Vattenfall to produce fossil-free steel using hydrogen, Kanthal developed an electric gas heating solution that could deliver hydrogen under the required conditions. This prototype would later evolve into the Prothal® portfolio.

In a major development, Kanthal and Danieli are preparing to supply the first electric process gas heater for commercial use in a DRI application. The unit, based on Prothal® DH technology, will be delivered to Emsteel in Abu Dhabi, marking a critical step toward real-world deployment at industrial scale. The groundwork for this breakthrough was laid in 2024, when Kanthal and Danieli signed a strategic partnership to jointly develop and industrialize full-scale electric gas heating systems for DRI plants.

What is Prothal®? 

Prothal® is Kanthal’s emerging portfolio of electric process gas heaters, engineered specifically for high-temperature, high-performance industrial use.

Key features include:

• Outlet temperatures up to 1,100°C. 
• Compatibility with multiple gases, including 100% hydrogen, hydrogen-nitrogen blends, nitrogen, BFG, COG, and air 
• Direct and indirect heating configurations depending on process needs 
• Power ratings from 100 kW to hundreds of megawatts, scalable to process requirements 
• Support for pressurized systems with low pressure drop and stable flow characteristics 
• Precise temperature control, ensuring ±1°C stability 
• Reduced energy losses and zero emissions when powered by fossil-free electricity 

Kanthal has built a dedicated 300 kW test bench for validation and development, where customer trials with pressurized hydrogen and nitrogen mixtures have been successfully conducted in 2024.

The business case

While the sustainability benefits are obvious, especially in a world of rising carbon taxes and regulatory pressures, the economic rationale is just as strong:

• Thermal efficiency up to 95% – Electric heating delivers energy where needed, without combustion losses. 
• Stable operations – Better process control means fewer defects and higher throughput.  
• Lower maintenance – No combustion residue, and fewer moving parts reduce downtime. 
• Safer environments – No open flames, cleaner air, and quieter operation. 
• Digitalization-ready – Electric systems integrate seamlessly with automation, IoT, and AI-driven control platforms. 

It’s already happening: Industrial adoption is underway

The gas-to-electric switch isn’t theoretical; it’s already taking place across industries. Kanthal has supported the transition in several downstream steel processes; however, the scope of the Prothal® portfolio extends much further. From cement and lime to pulp, petrochemicals, and beyond, Kanthal is actively developing electric gas heating solutions for sectors where high-temperature process gases remain essential. With decades of experience in high-performance heating across various applications, including semiconductors, glass, lithium-ion batteries, and more, Kanthal is uniquely positioned to make electrification viable throughout the industrial landscape.

As Dömstedt made clear at Green Steel World, electrifying process gas heating is no longer a technical fantasy or a future goal. It’s happening now. And it’s driven by engineering, economics, and necessity.

No rocket science. No gimmicks. With Prothal®, Kanthal is unveiling a solution that finally makes sense in the real world.