OIL, GAS & ENERGY
EVOLUTION, NOT REVOLUTION
H
Giampiero Frisio, President of ABB Electrification, outlines how an electrification roadmap for heavy industry starts with small steps that achieve big gains. Here he suggests where to begin... A good example of the benefits that
eavy industry faces a difficult balancing act: increase productivity while using energy more efficiently and cutting costs and emissions. As the shift away from fossil fuels gathers pace, the question is no longer whether to electrify, but how to turn that ambition into a practical business strategy.
Nearly four in five respondents to a recent global survey of 1,994 senior executives said geopolitical insecurity had made electrifying their businesses more urgent[1]. Eighty-eight percent expected electrification to improve competitiveness, and 90 percent said their operations would be electrified by 2035. This momentum is already visible as industrial companies modernise power infrastructure, replace ageing equipment and introduce electrical technologies that support productivity and sustainability.
Much of the technology needed to reduce emissions, improve efficiency and strengthen operational resilience is available today. The practical challenge is deciding where to start, and how to deliver value now while advancing long- term decarbonisation. Electrification is about more than cutting emissions. Modern electrical systems can improve energy efficiency, process control, reliability and visibility. They can also reduce maintenance, enhance safety and make it easier to integrate renewable energy. That matters even more at a time when geopolitical conflicts and disputes are restricting access to the fossil fuels that industry has traditionally relied on. In a recent poll, 91 percent of business executives cited energy security as a factor in their decision to electrify operations[2]. Many heavy industrial facilities were built around fossil fuels, and their combustion-based processes and equipment have remained largely unchanged for decades. Advances in power systems,
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automation, digital monitoring and electrification now make it increasingly practical to modernise these operations without disrupting production. For most industrial businesses, electrification happens one investment decision at a time. A steady cadence of upgrades reduces implementation risk, works with existing maintenance schedules and delivers measurable improvements along the way. The best results come from a practical roadmap that aligns technology upgrades with business priorities. The roadmap typically begins with an assessment of existing assets and energy use. Where are the reliability risks? Which equipment is approaching the end of its life? Where could energy be used more efficiently? The answers can reveal opportunities to strengthen electrical infrastructure, improve performance and replace ageing equipment. Later phases may include electrifying heating, introducing electric drives, integrating renewable energy and adopting advanced automation.
The priority should be projects that solve an immediate operational need while supporting long- term energy efficiency gains and decarbonisation. A phased approach spreads investment over time, reduces risk and builds confidence through measurable results and return on investment. Step 1: Start with the power infrastructure The electrical infrastructure itself is often the most effective place to begin. Many industrial sites rely on equipment that has performed reliably for decades but was never designed for today’s energy demands. As production grows and more processes are electrified, ageing switchgear, protection systems and distribution networks can become barriers to progress. Modernising these assets can deliver immediate gains in reliability and efficiency while creating a stronger foundation for future projects.
PROCESS & CONTROL ENGINEERING | OCTOBER 2026
modernisation can bring is BorsodChem MCHZ, a leading chemical producer. Spanning an area equivalent to 150 football fields, its plant supplies raw materials used in automotive manufacturing, construction and agriculture. With an aging power distribution network, the
reliability of the power supply had declined, and faults had begun to appear in the distribution equipment. Spare parts were not available, and some components needed to be improved. To ensure reliable and continuous operations, the company needed to modernise its energy infrastructure to create a stable and adaptable power network without disrupting production. Working with ABB, BorsodChem upgraded its critical electrical systems with new medium- voltage switchgear, cabling and cable routes, alongside upgrades to existing switchboards. The interconnected network integrates with digital control and data acquisition systems, improving reliability and operational flexibility. It also gives BorsodChem a power platform that can support future growth in production. Step 2: Prioritise reliability and retrofits In heavy industry, even a brief interruption can be costly. Unplanned downtime is estimated to cost companies an average of $187,500 per hour, while equipment failure accounts for around 42 percent of unexpected production stoppages[3]. It’s therefore essential to ensure that installed equipment offers the highest levels of reliability in terms of both performance and the ability to minimise disruption when maintenance is needed. The need for enhanced reliability was a major driving factor behind Australian steel producer InfraBuild’s decision to install an advanced VD4- AF vacuum circuit breaker technology as part of its melt shop modernisation. The upgrade was designed to improve reliability for the company’s
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