EMSTEEL’s groundbreaking electric gas heater pilot could transform global steelmaking emissions

EMSTEEL Group, which is one of the leading steel and building materials manufacturers in the UAE, has recently kicked off a pretty groundbreaking pilot project — they’re testing out the world’s first electric process gas heater (ePGH) for steelmaking. It’s quite an achievement, especially since they’ve been working closely with Danieli, a global leader in industrial technology. This initiative is seen as a major step forward in reducing carbon emissions within the steel industry.

Basically, the ePGH replaces traditional gas-fired heaters at EMSTEEL’s Direct Reduced Iron (DRI) plant located in Abu Dhabi, using a clean electric technology instead. And it’s not just a small change — this switch could eliminate over 2,200 tonnes of CO₂ emissions every year. That’s pretty significant. It aligns perfectly with EMSTEEL’s broader goal of cutting emissions by 40% by the year 2030 across its steel business. Plus, it supports the UAE’s ambitious Net Zero by 2050 initiative and the country’s ‘Operation 300 billion’ industrial strategy—so it’s part of a bigger national effort.

The development of the ePGH system was a real team effort, with close cooperation between EMSTEEL and Danieli’s R&D crews. The system has undergone extensive testing to ensure it can handle tough industrial conditions and deliver reliable performance. The initial pilot uses a 1.3-megawatt unit, but there are plans to potentially scale this up to a massive 22.7-megawatt version. If successful, this could not only change how thermal process heating is done in steelmaking but also set an industry-wide example for large-scale electric upgrades.

Kanthal, a division of Alleima, and Danieli are jointly supplying this pilot heater. It includes Kanthal’s innovative Prothal® DH technology — a solution designed to boost energy efficiency and completely eliminate the CO₂ emissions that usually come from burning fossil fuels in heating processes. The plan is to deliver the first unit by early 2026, putting the UAE right at the forefront of adopting cutting-edge sustainable manufacturing techniques.

Engineer Saeed Ghumran Saeed Al Remeithi, the Group CEO at EMSTEEL, emphasizes that the company’s push toward scalable clean tech is about leading the way in sustainable manufacturing in the region. “By adopting scalable clean technologies, we’re not only speeding up our own green steel journey,” he explained, “but also reinforcing the UAE’s standing as a global innovation hub for industry.” He added that their ultimate goal is to create solutions that have a lasting positive impact on the environment, the economy, and future generations.

EMSTEEL is already impressive — operating 16 high-tech plants that produce around 3.5 million tonnes of steel and 4.6 million tonnes of cement each year. Their products support major infrastructure projects within the UAE and in over 70 international markets. The company’s efforts to cut emissions have already seen a 23% reduction in Scope 1 and Scope 2 emissions intensity. As of 2023, their total Scope 1 and 2 emissions totaled about 4.5 million tonnes of CO₂, marking real progress toward their net-zero targets.

This electric heater project isn’t just about environmental benefits. It’s also scalable and could be applied across the steel industry worldwide. Replacing fossil fuel-based thermal processes with electric systems powered by renewable energy is seen as a pretty pivotal move toward overall decarbonisation.

Industry data shows that steel manufacturing has historically been responsible for roughly 7-9% of global CO₂ emissions since it’s such an energy-heavy, carbon-intensive industry. Innovations like EMSTEEL’s ePGH could be a game-changer—especially for regions that are aiming to decarbonise through clean energy adoption. If this pilot proves successful, it might well encourage similar retrofits around the globe, helping to decarbonise steel production at a larger scale.

The project also strengthens Abu Dhabi and the UAE’s reputation as players in sustainable industrial innovation. Backed by ADQ, a sovereign investment firm focused on key infrastructure and supply chains, EMSTEEL demonstrates what’s possible when public and private sectors team up to promote climate-friendly tech.

As the delivery date nears, a lot of attention will be focused on how the pilot performs operationally, particularly in terms of energy efficiency. The insights gained could influence the future of steel manufacturing—not just here in the Middle East but around the world. By proving that electric heating can handle the demands of heavy industry, EMSTEEL and its partners are paving the way toward a cleaner, more sustainable industrial future.

Source: Noah Wire Services