Industry and energy are converging into a shared technology field

Digital transformation shapes the move towards connected, self-optimising and more resilient processes, in industry as well as in energy systems. Sensor technology, the Industrial Internet of Things, digital twins, edge computing and artificial intelligence create the basis for monitoring plants and grids in real time, predicting conditions more precisely and automating decisions to a greater degree. In manufacturing, this promotes predictive maintenance, flexible production control and higher resource efficiency in particular; in the energy world, these technologies enable better integration of renewable generation, the inclusion of decentralised prosumers and the intelligent coupling of electricity, heat and industrial systems. Industry 4.0 thus becomes an enabler for more productive plants and, at the same time, for a robust, smart energy system.

Key technology trends here are the electrification of process heat and drives, the expansion of power-to-X pathways (electrolysis, synthetic fuels and feedstocks), the integration of hydrogen and CO₂ infrastructures, and digital control and flexibility solutions for load-variable generation and consumption. Direct electrification with green electricity is systemically cost-effective and, together with efficiency measures, makes the largest contribution to reducing CO2-emissions; for process-related emissions, hydrogen direct reduction in the steel industry, carbon capture and storage and carbon capture and utilisation options (CCS, CCU) and biomass-based alternatives are gaining importance. In parallel, sector coupling requires grid expansion, intelligent load management and storage concepts, and standardised measurement and certification systems for green products in order to create planning certainty and market demand.

In industrial electrification, heat pumps, electrode boilers and electric arc furnaces are opening up new efficiency potential, particularly in process heat. In manufacturing, DC grids, energy storage and the integration of renewable energy sources are also gaining importance. This requires a capable expansion of renewable power generation and grid infrastructure. Distribution grids are developing into bidirectional, intelligent systems that coordinate volatile feed-in, flexible loads and storage. Digital grid control technology, demand response, artificial intelligence and predictive maintenance support stability and cost-effectiveness. With rising electrification, energy efficiency in the use of electrical energy is also becoming ever more important: electric motors account for a considerable share of the electricity used in industry; with high-efficiency motors, demand-based speed control and the use of frequency converters, motor-driven systems can typically save 20 to 30 per cent of energy. Electronics and semiconductor technology provide the basis for this: power semiconductors made from silicon carbide or gallium nitride reduce switching and conduction losses, while microcontrollers, sensors and digital control algorithms control drives precisely and predictively. Innovative power management solutions monitor, regulate and optimise electrical power and all energy flows, from voltage conversion at plant level to intelligent distribution in factories, from EV charging stations to the power grids.

The share of decentralised, weather-dependent generators such as wind and solar power in energy supply is growing continuously. This increases the demands on flexibility, grid stability and precise coordination of generation and consumption. The most important technology trends include sector coupling, storage solutions, the electrification of process heat, power-to-X applications, and digital control and forecasting systems. Industrial DC grids are also gaining importance, because they can be connected particularly efficiently with decentralised generators, storage and DC loads. What matters is an energy system that not only absorbs more electricity from renewable sources, but also distributes it intelligently and makes it usable for industry.

Expanding the power grids and integrating storage technologies are central building blocks for a secure, resilient and climate-neutral energy supply, particularly in the context of increasingly electrified industrial production. With a growing share of fluctuating renewable energies in the electricity mix, it is becoming more necessary to balance generation peaks and troughs with flexible storage capacity and, at the same time, to expand the transport capacity of the grids. Only in this way can the balance between supply and demand be guaranteed at all times, and security of supply be ensured for industry and society.

The most important technology trends include the massive expansion of high-voltage direct current (HVDC) transmission for efficient long-distance transport of renewable energy, the digitalisation and automation of the grids (smart grids), and the use of power electronics and FACTS systems for grid stabilisation. In parallel, battery storage, especially lithium-ion systems for short-term storage, and pumped-storage power plants are gaining importance, while technologies such as hydrogen electrolysis, power-to-gas and thermal storage are becoming increasingly relevant for medium and long storage durations. Standards such as DIN EN IEC 62933 and application rules such as VDE-AR-N 4100 enable the safe and grid-friendly integration of these storage systems.

Geopolitical tensions, fragile raw material markets and growing cyber threats make the resilience of supply chains and energy systems the decisive factor for the future of industrial production. Trade conflicts, sanctions, natural disasters and political instability can today jeopardise the supply of semiconductors, battery materials, rare earths or components for power grids within a short time. Particularly critical is the high concentration of the extraction and processing of certain raw materials that are indispensable for renewable energies, storage, power electronics and grid expansion. Companies and energy suppliers therefore have to broaden their supply chains, reduce dependencies, plan stock levels strategically and advance recycling and material substitution. At the same time, digital technologies are intended to make risks visible early: IoT sensor technology, big data analytics and artificial intelligence support forecasting and adaptive planning, digital twins simulate disruptions and alternative supply scenarios. Blockchain can improve traceability, while additive manufacturing enables more flexible spare-parts supply. In energy systems, decentralised microgrids, cyber-resilient grid architectures, secure communication standards and automated recovery mechanisms are also gaining importance. Because with increasing connectivity, it is not only efficiency that grows, but also the attack surface for cyberattacks.

The pace of innovation keeps accelerating: new technologies now move from research into industrial application faster, and new products are brought to market in ever shorter cycles. At the same time, the demands on integration, standardisation and cost-effectiveness are also rising. Companies therefore have to do more than convince in pilot projects: they need to consider scalability, interoperability, cybersecurity, the availability of skilled staff and stable supply chains early on, in order to actually roll out new solutions on a broad scale.

Against this background, time-to-market and the ability to innovate are moving further into the centre of attention. In manufacturing, the focus is above all on connected automation, AI-supported process control, digital twins, edge and cloud computing, and collaborative robotics. In energy plants and grids, intelligent power electronics, storage, renewable generation, hydrogen technologies, smart grids and data-based grid management are driving the change. What is decisive is that innovation not only emerges, but can be scaled quickly, robustly and economically.