Unlocking Electrification for High-Duty Industrial Applications

As industries across the globe race to meet ambitious decarbonization targets, the electrification of thermal processes has emerged as a critical pathway to reducing greenhouse gas emissions. While low voltage electric resistance heating (ERH) has long been a staple in industrial applications, the emergence of medium voltage ERH systems is transforming what’s possible—especially for high-duty, centralized thermal loads.

In this blog, we explore how medium voltage ERH is enabling a new era of industrial electrification, offering unmatched efficiency, scalability, and cost-effectiveness.

Why Medium Voltage Matters

Traditional low voltage electric resistance heating (ERH) systems (operating below 1,000 V) offer a reliable and well-established solution for smaller, decentralized heating loads. They are straightforward to implement, widely supported, and well-suited for applications with modest power demands. However, in multi-megawatt applications, these systems face limitations related to high current requirements, increased infrastructure complexity, and greater energy losses. 

Medium voltage ERH systems (1,000 V to 7,200 V) address these challenges head-on through:

• Lower Current Requirements
  For example, a 1 MW load at 480 V requires over 1,200 amps, while the same load at 4.16 kV requires just 139 amps
• Higher Efficiency
  Medium voltage systems achieve average efficiencies of ~99%, compared to ~96% for low voltage systems
• Reduced Infrastructure
  By eliminating the need for step-down transformers and minimizing wiring, these systems simplify installation and reduce capital expenditure

Efficiency Gains That Scale

In continuous, high-load operations, even small improvements in efficiency translate into significant cost savings. Medium voltage ERH systems not only reduce energy losses but also lower operational and maintenance costs due to their simple, robust design with no moving parts.

By applying power directly to the heating elements at medium voltage, facilities can:

• Avoid transformer losses.
• Minimize cable heating and I²R losses.
• Reduce the footprint and complexity of electrical infrastructure.

Real-World Impact: Use Cases

1. Chemical Manufacturing – Long-Distance Heat Delivery
A chemical plant needed to supply heat over a 350-meter distance to support octane production. A 3 MW, 6,300 V ERH system was deployed to minimize cable losses and ensure consistent, efficient heat delivery. The result? A reduction of approximately 6,000 tonnes of CO₂ annually compared to fossil fuel alternatives.

2. Fuel Refinery – Seamless Integration with Existing Infrastructure
A refinery expanding its biodiesel production sought to decarbonize its vacuum distillation unit. By installing two 3.85 MW medium voltage ERH systems, the facility avoided the need for new low voltage switchgear and cabling. This upgrade is part of a broader initiative expected to cut between 1.2 and 1.7 million tonnes of CO₂ across the company’s value chain.

Proven Technology, Ready for Scale

Medium voltage ERH systems are a proven, fully mature technology with a solid track record of successful deployment around the world for over a decade. Built on the same well-established principles that have underpinned electric resistance heating for more than a century, these systems have achieved the highest Technology Readiness Level (TRL 9) and are ready for widespread adoption today.

Conclusion: A Smarter Path to Decarbonization

For industries seeking to electrify large-scale thermal processes without compromising reliability or efficiency, medium voltage ERH offers a compelling solution. It combines the simplicity and precision of electric resistance heating with the scalability and cost-effectiveness needed for today’s decarbonization goals.

As the pressure to reduce emissions intensifies, medium voltage ERH stands out as a proven, practical, and powerful tool in the industrial energy transition.