Arthur Moslow, Electrification Project Manager, Kanthal.But there’s a paradox decision-makers can’t ignore. RTOs destroy VOCs, yet when gas-fired, they generate CO₂ at the same time.

At Kanthal, we put an end to this contradiction.

“Electrification is the way forward,” says Arthur Moslow, Electrification Project Manager at Kanthal. “It allows RTOs to keep doing what they were designed for, but without adding new emissions. Instead of being just a compliance tool, they become part of a company’s decarbonization strategy.”

The problem with gas-fired systems

Around 90 percent of RTOs still run on burners, and on the surface, the setup looks straightforward: gas heats the chamber, VOCs combust, and the process repeats.

The reality is more complicated as gas-fired systems come with built-in drawbacks: 

• Scope 1 emissions: Every cubic meter of gas adds directly to a company’s footprint.
• Fuel costs: Price volatility makes long-term operating costs unpredictable.
• Maintenance: Gas-fired systems are heavy on maintenance and prone to failures.
• Safety: Any gas-fired system carries risks of leaks and explosions.

“Most end users don’t think about any of this. They press a button and expect it to run. But the fuel choice behind that button press has huge consequences for emissions, costs, and safety. That’s why OEMs are central to this transition. They’re the ones in a position to offer customers a cleaner, more reliable alternative,” asserts Moslow.

Why electrification changes the picture

For companies balancing compliance with decarbonization targets, electrification turns the RTO from a regulatory requirement into a strategic advantage.

Electrifying an RTO doesn’t mean a full design overhaul. It simply replaces the gas burner and its infrastructure with an electric heating system.

The benefits are immediate:

• Zero Scope 1 emissions: No on-site combustion.
• Scope 2 reductions: Nearly carbon-free when paired with fossil-free electricity.
• Energy efficiency: Electric systems can achieve nearly 100% thermal efficiency.
• Process stability: Faster, more precise temperature and process control.
• Lower maintenance: The absence of combustion byproducts reduces the need for maintenance.
• Improved safety: No open flames, leaks, or combustion risks.

“For companies balancing compliance with decarbonization targets, electrification turns the RTO from a regulatory requirement into a strategic advantage,” Moslow notes.

“The advantages of electrification hold across various industries. However, the priorities may differ. At Kanthal, our strength lies in decades of expertise in electric heating, allowing us to adapt that knowledge to any application,” Moslow claims.

A portfolio built for every need

One barrier to adoption has been the misconception that electric heating isn’t flexible enough for different RTO designs. Kanthal’s portfolio covers the full spectrum:

• Kanthal® Air heating cassettes – For RTOs operating up to 900°C (1,650°F), allowing VOC-laden air to pass directly over the heating surface for efficient transfer.
• Tubothal® elements – For systems up to 1,100°C (2,010°F), offering durability and reliability across industries.
• Globar® SiC elements – For specific atmospheres and conditions where Silicon Carbide is the best fit.
• Kanthal® Flow Heater – A unique option for processes like automotive painting, where fresh heated air must be introduced into the system.

“The right solution always depends on the application. Temperature, gas composition, industry conditions, they all matter,” adds Moslow.

The value of expertise

Electrifying an RTO raises critical questions for decision-makers:

• Risk: Will the system perform as required?
• ROI: How will upfront investment compare to long-term savings?
• Compliance: Will it support environmental targets and regulatory requirements?
• Validation: Can the solution be trusted in demanding industrial environments?

“These are the concerns we hear from OEMs every day. No one wants to gamble with performance or credibility. They need proof, and they need a partner who can stand behind the solution,” admits Moslow.

He explains that Kanthal’s value extends far beyond its product range. The company boasts decades of experience in electric heating, supported by proprietary tools, models, and data. This includes material-selection spreadsheets that consider various atmospheres and chemical exposures, as well as advanced CFD (Computational Fluid Dynamics) modeling for heat transfer. Together, these resources equip OEMs with custom validated designs, giving them the confidence that their systems will perform as required.

And this is not just theory. Kanthal has supplied the RTO industry with solutions since the 1990s, including Tubothal® elements and APM tubes from Sweden. What’s new today is the shift: a more coordinated, global approach to RTO electrification, driven by worldwide demands for decarbonization and reliability.

For Moslow, the future of RTOs is electric. Technology exists, the expertise is in place, and industries are looking for solutions that can deliver.

“Electrification isn’t a question mark anymore, it’s a real, working solution. Our role at Kanthal is to give OEMs the confidence to move forward, knowing the systems they deliver will stand the test of time. That’s what makes this shift so exciting,” he concludes.