Direct Current for
Decarbonising Industry

We need more energy in the future but less CO₂. Direct current aims to make both possible.

By 2030, global energy demand will increase by 30%. The challenge lies in meeting this growing demand without burning fossil fuels, says Hartwig Stemmberger, Manager at Eaton Technologies, during the NEFI (New Energy for Industry) conference in Vienna. However, existing energy grids are already reaching their limits, and expansion projects in Europe often take decades. For him, a viable approach is the expansion of DC in industry.

Why Direct Current?

DC is not a new technology—it is already widely used, from photovoltaic systems to battery storage and electric vehicles. But what makes DC so attractive for industrial applications? “The good thing about direct current is that I don’t have to invent it,” says Hartwig Stemmberger during the NEFI Talk “Innovative DC Solutions in Industry” at Vienna’s MuseumsQuartier at the end of October. “It already exists almost everywhere. In photovoltaics, wind power, and batteries for electric vehicles, DC is becoming increasingly economical.”

The NEFI innovation network, composed of researchers, technology providers, and companies, aims to support industrial businesses in decarbonisation. One approach is the adoption of DC. Stemmberger, who also chairs the international Open DC Alliance, highlighted the advantages of DC networks in an industrial context during the NEFI Talk. For example, consider the cabling from a transformer to the inverter for a 7.5-kW motor driven by a frequency converter. For every kilometer of cable in a two-shift operation, DC saves 10 cents per kilowatt-hour due to lower losses and materials (DC requires only two phases). “Would you like to save €2,500 per kilometer of cable?” Stemmberger asked the audience. “Ask your building manager!” Chuckles could be heard in the crowd.

Hartwig Stammberger at the NEFI Technology Talk
"Innovative DC solutions in industry"

The Open DC Alliance

Stemmberger is successfully advancing the integration of DC systems in industry, such as coordinating two research projects with partners like BMW, KUKA, and Fraunhofer. He also heads the Open DC Alliance (ODCA), a network promoting DC in industrial contexts, working on standards for voltages, grounding, and electromagnetic compatibility. Currently, 71 institutions across 11 countries are members of the ODCA. The goal is to establish a sustainable and internationally compatible DC infrastructure.

Beyond the technological benefits, DC also offers tangible economic advantages. Industrial companies not only pay for energy consumption but also for maximum peak loads. Reducing these peaks significantly lowers energy costs. Furthermore, regenerative braking energy can be fed back into a DC grid, and the simple integration of energy storage increases resilience to power outages.

Challenges Ahead

Such praise invites skepticism. “What’s the downside of DC?” asked a voice from the audience. Stemmberger quipped, “The downside of direct current is that we’ve been doing everything with alternating current for 120 years.” A humorous remark but also true. While DC is a key to greater efficiency and sustainability in many areas, comprehensive standardisation is still lacking. This knowledge is now being rapidly developed. Networks such as the Open DC Alliance (ODCA) or the Austrian Electrotechnical Association (OVE) provide companies with information on potential savings and implementation options.

Here you can find more information about the project Austrian DC Pilot Factory.