NOW
Ready to electrify.
APPLICATIONS
- Low- and medium-temperature drying
- Selected annealing processes
- Auxiliary heating
- Electric boosting
- Suitable batch processes
CHARACTER
- Mature technologies
- Manageable integration
- Near-term opportunity
PROJECT · GLASS & CERAMICS
Electrifying process heatacross six manufacturing sites.
A European manufacturer needed to understand where electrification could replace fossil-fired process heat across a diverse production portfolio — and which investments should happen first.
Terravia developed a multi-site pathway combining technical feasibility, energy-system modelling and investment sequencing.
- Technology & Economics
- Investment Roadmaps
AT A GLANCE
From six individual sitesto one investment strategy.
- 6
- manufacturing sites assessed
- 68%
- of process-heat emissions addressed
- €42m
- priority investments identified
- 2030+
- roadmap extending beyond 2030
- Client
- European industrial manufacturer
- Sector
- Glass & Ceramics
- Geography
- Europe
- Scope
- Multi-site process-heat transition
- Expertise
- Technology & Economics · Investment Roadmaps
THE CHALLENGE
The question was notwhether to electrify.It was where, howand when.
The company operated six manufacturing sites with different thermal processes, asset ages, electricity infrastructure and production requirements.
Some applications appeared ready for direct electrification. Others required hybrid technologies, infrastructure upgrades or further technology development.
A single technology assumption across the portfolio would have produced the wrong investment plan.
THREE QUESTIONS
- 01
Where is electrification technically viable?
Determine which thermal processes could move away from fossil fuels without compromising temperature, throughput or product quality.
- 02
Where does it make economic sense?
Understand how capital costs, electricity prices, gas prices and carbon costs affect the business case.
- 03
What should happen first?
Sequence investments around asset replacements, grid capacity and the maturity of each technology.
PORTFOLIO BASELINE
Six sites.Six different starting points.
Terravia established a common baseline across the portfolio before comparing technology options.
Each site was assessed at process level to understand where energy was consumed, how heat was generated and which constraints would affect electrification.
BASELINE INCLUDED
- Thermal energy demand
- Operating temperatures
- Load profiles
- Existing furnace and kiln assets
- Electrical infrastructure
- Asset age and replacement cycles
- Site emissions
- Production constraints
| Site | Primary Process | Existing Heat | Asset Position | Electrification Readiness |
|---|---|---|---|---|
| Site A | Melting | Natural gas | Mid-life | Medium |
| Site B | Annealing | Natural gas | Replacement approaching | High |
| Site C | Drying | Natural gas | Modern | High |
| Site D | Firing | Natural gas | Mid-life | Medium |
| Site E | Melting | Gas + electric boost | Rebuild approaching | High |
| Site F | Finishing heat | Natural gas | Mixed assets | High |
WHERE TO ELECTRIFY
Not every megawattof heat is equal.
The assessment separated process heat into applications with different levels of electrification readiness.
This allowed the company to focus capital on opportunities where the technology was credible while preserving optionality elsewhere.
NEXT
Electrify with enabling investment.
APPLICATIONS
- Larger thermal systems
- Hybrid furnace configurations
- High-capacity electric heating
- Processes constrained by existing grid capacity
CHARACTER
- Technology available
- Infrastructure dependency
- Asset-cycle alignment required
LATER
Preserve the option.
APPLICATIONS
- Selected high-temperature melting
- Processes with major product-quality constraints
- Assets requiring fundamental redesign
CHARACTER
- Technology developing
- Higher uncertainty
- Future decision gates
TECHNOLOGY & ECONOMICS
Compare the optionson the same basis.
Terravia screened electrification technologies against the technical requirements of each process before modelling the strongest candidates in greater detail.
Electric Resistance
Mature and flexible electrical heating for suitable thermal applications.
Induction
High-efficiency direct heating for compatible materials and processes.
Electric Furnaces
Full or substantial replacement of combustion-based thermal systems.
Electric Boosting
Additional electrical energy introduced into existing furnace configurations.
Hybrid Systems
Electricity combined with combustion to reduce fossil demand while maintaining operational flexibility.
Industrial Heat Pumps
Efficient electrification for lower-temperature thermal demand and heat recovery.
ASSESSMENT CRITERIA
Technical, operational,infrastructure and economic.
Technical
- Temperature range
- Process compatibility
- Throughput
- Product quality
- Technology maturity
Operational
- Controllability
- Reliability
- Maintenance
- Retrofit complexity
- Production disruption
Infrastructure
- Electrical capacity
- Connection requirements
- Transformers
- Site distribution
- Implementation lead time
Economic
- CAPEX
- OPEX
- Energy prices
- Carbon exposure
- Asset lifetime
THE BUSINESS CASE
Electrification changesthe economics of heat.
Replacing gas with electricity changes both capital requirements and long-term operating exposure.
Rather than relying on one energy-price forecast, Terravia tested each technology across multiple futures.
| Scenario | Electricity | Gas | Carbon | Electrification Case |
|---|---|---|---|---|
| Current market | Moderate | Moderate | Current | Selective |
| High gas | Moderate | High | Rising | Strong |
| Low-carbon power | Low | Moderate | Rising | Very strong |
| High electricity | High | Moderate | Rising | Constrained |
Electricity price
The largest operating-cost driver for many electrified processes.
Gas price
Determines the competitiveness of retaining conventional thermal systems.
Carbon price
Changes the long-term cost of continued fossil-fuel consumption.
Utilisation
High operating hours can amplify relatively small differences in energy efficiency.
Asset timing
Replacing equipment at the natural end of its life can materially improve the investment case.
PORTFOLIO PRIORITISATION
One pathway.Different timing by site.
The six sites were positioned according to emissions impact, technical readiness and investment attractiveness.
PRIORITY 01 · SITE B
Electrify at next replacement.
Mature technology, approaching asset replacement and sufficient electrical capacity.
IMPACT
- High readiness
- Strong economics
- Near-term deployment
PRIORITY 02 · SITE E
Integrate electrification into the furnace rebuild.
The upcoming rebuild creates a rare opportunity to increase electrical contribution without premature asset retirement.
IMPACT
- High emissions potential
- Strategic asset window
- Infrastructure preparation required
PRIORITY 03 · SITES C & F
Deploy targeted measures.
Multiple smaller applications can electrify using mature technologies with relatively limited integration risk.
IMPACT
- Fast implementation
- Moderate investment
- Portfolio-wide learning
PREPARE · SITES A & D
Build the conditions for later conversion.
Major process constraints and asset timing make immediate full conversion unattractive.
IMPACT
- Grid preparation
- Pilot opportunities
- Future decision gates
INVESTMENT ROADMAP
Move now where the case is clear.Prepare where it is not.
The roadmap deliberately separates investments that are robust today from decisions that should remain conditional on technology and energy-market development.
2027–2028 · NO-REGRET ACTIONS
Start with mature opportunities.
ACTIONS
- Electrify mature auxiliary processes
- Deploy selected heat-pump applications
- Begin Site B conversion
- Upgrade monitoring and controls
- Secure grid-capacity studies
€8m
Investment
2028–2030 · SCALE
Expand the proven pathway.
ACTIONS
- Expand electrification across Sites C and F
- Complete Site B transition
- Reinforce selected electrical infrastructure
- Prepare Site E furnace rebuild
€14m
Investment
2030–2033 · TRANSFORM
Use the major asset window.
ACTIONS
- Introduce high-electric configuration at Site E
- Deploy additional hybrid systems
- Expand site electrical capacity
- Reassess developing high-temperature technologies
€20m
Investment
2033+ · DECISION WINDOW
Preserve future choices.
ACTIONS
- Reassess Sites A and D
- Evaluate full-electric furnace technologies
- Respond to electricity-market development
- Progress toward remaining thermal emissions
THE RESULT
A portfolio strategybuilt for investment decisions.
- 68%
- Process-heat emissions addressed
- €42m
- Priority investments identified
- 6
- Sites assessed
- 2030+
- Long-term roadmap
The pathway identified credible technologies capable of addressing more than two-thirds of existing process-heat emissions.
Capital requirements were translated into a phased programme rather than a single portfolio-wide commitment.
Each manufacturing site received a pathway reflecting its own processes, assets and infrastructure.
Near-term actions were connected to future asset cycles and technology decision points beyond 2030.
PROJECT DELIVERABLES
The evidence behindthe roadmap.
Process-Heat Baseline
Site-level mapping of thermal energy, emissions, processes and major assets.
Electrification Screening
Assessment of technically credible electrical technologies for each major heat application.
Techno-Economic Model
Comparable CAPEX and operating-cost analysis across technologies and energy scenarios.
Grid & Infrastructure Assessment
Identification of electrical-capacity constraints and enabling investments across the portfolio.
Site Prioritisation
Ranking of opportunities according to emissions impact, technical readiness, economics and asset timing.
Investment Roadmap
A phased multi-site programme with priority investments, future decision gates and enabling actions.
EXPERTISE USED
Technical evidence.Investment clarity.
Technology & Economics
Compare electrification technologies, infrastructure requirements and future operating economics on a consistent basis.
Explore Technology & EconomicsInvestment Roadmaps
Turn the preferred technologies into a sequenced programme aligned with assets, infrastructure and capital cycles.
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View projectSTART A CONVERSATION
Where should you electrify first?
If you are evaluating process-heat electrification across one site or an entire manufacturing portfolio, Terravia can help identify where the technology works, where the economics hold and which investments should come first.
Talk to our team