Converting electricity into heat offers the opportunity to make of use large scales of renewable (surplus) energy in the long run in order to reduce shut-downs of renewable power plants and to substitute fossil fuels. Electrification seems to be also very promising for industrial heat applications, as it enables high process temperatures to be achieved in a tailor-made and efficient way and enables the utilisation of other energy sources like waste heat, geothermal or ambient heat (via heat pumps). This article analyses theoretical and technical electrification potentials of Steam Generation and Other Process Heat Generation in the following energy-intensive branches: iron & steel, non-ferrous metal, iron foundries, refineries, base chemicals, glass, cement clinker and paper industry in Germany. Literature research, expert interviews as well as own modelling were conducted to determine potentials and their implementation barriers. Based on these methods, market potential to electrify industrial steam generation was estimated. On the basis of two climate protection scenarios, the effects of both a monovalent and a hybrid industrial power-to-heat strategy were quantified with regard to greenhouse gas reduction and energy efficiency (primary energy saving). The pathway towards electrification will be reflected by criteria such as path dependency, dependency of infrastructure and system compatibility. Recommendations for research and development as well as policies are derived from the overall analysis. The article shows that electrification can be an important option to achieving high CO2-savings in the industrial heating sector in a long-term perspective. However, the scenario calculations show that electrification does not in itself guarantee reduction of greenhouse gases or savings of primary energy. To reach these goals, it is essential to further develop industrial heat pumps and to map electrification and further development of renewable energy (including infrastructure such as power networks and storage facilities) in a concerted strategy.
Die Forschung der FVEE-Institute zum Einsatz von klimaneutral erzeugtem Wasserstoff in der Industrie deckt sowohl technische Aspekte für einzelne Prozesse ab als auch systemanalytische Betrachtungen, die die Einsatzmöglichkeiten von Wasserstoff am einzelnen Standort oder für bestimmte Branchen in Deutschland bzw. Europa untersuchen.
Die Motivation zum Einsatz von Wasserstoff ergibt sich aus drei Gründen:
1. In der stofflichen Verwendung wird Wasserstoff als Molekül benötigt und kann deshalb auch nicht durch andere Energieträger substituiert werden. So wird Wasserstoff bereits heute in großen Mengen in der Ammoniaksynthese (Haber-Bosch-Verfahren) sowie in den Raffinerien benötigt.
2. Eine weitere Verwendungsart für Wasserstoff ergibt sich aus seiner Fähigkeit, Sauerstoff aus Eisenerz chemisch zu binden. Beim Einsatz in Direktreduktionsanlagen kann Wasserstoff als Reduktionsmittel eingesetzt werden, um Eisenerz zu Roheisen zu reduzieren.
3. Als dritte Option gerät die energetische Verwendung von Wasserstoff in der Industrie zunehmend in den Fokus der energiepolitischen Debatten. Hier steht Wasserstoff in einem klimaneutralen System direkt in Konkurrenz zu anderen Energieträgern wie Strom und Biomasse.
The paper describes quantitative scenarios on a possible evolution of the EU petrochemical industry towards climate neutrality. This industry will be one of the remaining sectors in a climate neutral economy still handling hydrocarbon material to manufacture polymers. Concepts of a climate neutral chemical industry stress the need to consider the potential end-of-life emissions of polymers produced from fossil feedstock and draft the vision of using renewable electricity to produce hydrogen and to use renewable (hydro)carbon feedstock. The latter could be biomass, CO2 from the air or recycled feedstock from plastic waste streams.
The cost-optimization model used to develop the scenarios describes at which sites investments of industry in the production stock could take place in the future. Around 50 types of products, the related production processes and the respective sites have been collected in a database. The processes included cover the production chain from platform chemicals via intermediates to polymers. Pipelines allowing for efficient exchange of feedstock and platform chemicals between sites are taken into account as well. The model draws on this data to simulate capacity change at individual plants as well as plant utilization. Thus, a future European production network for petrochemicals with flows between the different sites and steps of the value chain can be sketched.
The scenarios described in this paper reveal how an electrification strategy could be implemented by European industry over time with minimized societal costs. Today's existing assets as well as geographical variance of energy supply and the development of demand for different plastic sorts are the major model drivers.
Finally, implications for the chemical industry, the energy system and national or regional governments are discussed.
The German federal state of North Rhine-Westphalia (NRW) is home to important clusters of energy-intensive basic materials industries. 15% of the EU's primary steel as well as 15% of high-value base chemicals are produced here. Together with refinery fuels, cement, lime and paper production (also overrepresented in NRW) these are the most carbon-intensive production processes of the industrial metabolism. To achieve the ambitious regional and national climate goals without relocating these clusters, carbon-neutral production will have to become standard by mid-century. We develop and evaluate three conceptual long-term scenarios towards carbon-neutral industry systems for NRW for 2050 and beyond:
* a first scenario depending on carbon capture and storage or use for heavy industries (iCCS),
* a second scenario sketching the direct electrification of industrial processes (and transport) and
* a third scenario relying on the import of low carbon energies (e.g. biomass, and synthetic fuels (like methanol) for the use in industries and transport. All scenarios share the assumption that electricity generation will be CO2-neutral by 2050.
For all three scenarios energy efficiency, primary energy demand for energy services and feedstock as well as the carbon balance are quantified. We apply a spatial-explicit analysis of production sites to allow for discussion of infrastructure re-use and net investment needs. Possible symbiotic relations between sectors are also included. The robustness of the three conceptualised future carbon-neutral industry systems is then analysed using a multi-criteria approach, including e.g. energy security issues and lock-ins on the way to 2050.
Heat integration and industrial symbiosis have been identified as key strategies to foster energy efficient and low carbon manufacturing industries (see e.g. contribution of Working Group III in IPCC's 5th assessment report). As energy efficiency potentials through horizontal and vertical integration are highly specific by site and technology they are often not explicitly reflected in national energy strategies and GHG emission scenarios. One of the reasons is that the energy models used to formulate such macro-level scenarios lack either the necessary high technical or the spatial micro-level resolution or both. Due to this lack of adequate tools the assumed huge existing potentials for energy efficiency in the energy intensive industry cannot be appropriately appreciated by national or EU level policies. Due to this background our paper describes a recent approach for a combined micro-macro energy model for selected manufacturing industries. It combines national level technical scenario modelling with a micro-modelling approach analogous to total site analysis (TSA), a methodology used by companies to analyse energy integration potentials on the level of production sites. Current spatial structures are reproduced with capacity, technical and energy efficiency data on the level of single facilities (e.g. blast furnaces) using ETS data and other sources. Based on this, both, the investments in specific technologies and in production sites are modelled and the evolvement of future structures of (interconnected) industry sites are explored in scenarios under different conditions and with different objectives (microeconomic vs. energy efficiency optimization). We further present a preliminary scenario that explores the relevance of these potentials and developments for the German steel industry.
This paper draws upon an extensive transdisciplinary scenario development in the context of the stakeholder oriented preparation of the climate protection plan of the German federal state North Rhine-Westphalia, which is home to the most important heavy industry cluster in Europe. In that context we developed differentiated bottom up climate change mitigation strategies and scenarios for the major energy intensive industries aluminium, iron and steel, cement, lime, paper and steam cracker for olefin production together with representatives of industry as well as society.
The Port of Rotterdam is an important industrial cluster mainly comprising of oil refining, chemical manufacturing and power and steam generation. In 2015, the area accounted for 18 % of the Netherlands' total CO2 emissions. The Port of Rotterdam Authority is aware that the port's economy is heavily exposed to future global and EU decarbonization policies, as the bulk of its activities focuses on trading, handling, converting and using fossil fuels. Based on a study for the Port Authority, our paper explores possible pathways of how the industrial cluster can keep its strong market position in Europe and still reduce its CO2 emissions by 98 % by 2050. The "Biomass and CCS" scenario assumes that large amounts of biomass can be supplied sustainably and will be used in the port for power generation as well as for feedstock for refineries and the chemical industry. Fischer-Tropsch fuel generation plays an important role in this scenario, allowing the port to become a key cluster for the production of synthetic fuels and feedstocks in Western Europe. The "Closed Carbon Cycle" scenario assumes that renewables-based electricity will be used at the port to supply heat and hydrogen for the synthetic generation of feedstock for the chemical industry. The carbon required for the chemicals will stem from recycled waste. Technologies particularly needed in this scenario are water electrolysis and gasification or pyrolysis to capture carbon from waste, as well as technologies for the production of base chemicals from syngas. The paper compares both scenarios with regard to their respective technological choices and infrastructural changes. The scenarios’ particular opportunities and challenges are also discussed. Using possible future pathways of a major European petrochemical cluster as an example, the paper illustrates options for deep decarbonisation of energy intensive industries in the EU and beyond.
Im Rahmen der Energiewende haben sich erneuerbare Energien zur Stromerzeugung in Deutschland bereits etabliert. Um jedoch das volle Potenzial der Reduktion von fossilen Energien und Treibhausgasen (THG) auszuschöpfen, muss aus der Energiewende auch eine Wärmewende werden. Der Energieeinsatz für die Wärmebereitstellung der Industrie betrug im Jahr 2012 etwa 535 TWh (22 % des Endenergiebedarfs Deutschlands), hauptsächlich bereitgestellt durch Erdgas (48 %) und Steinkohle (17 %) 1. Damit wurden für die Wärmebereitstellung im Industriesektor rund 159 Mio. t CO2-äq emittiert, was 17 % der THG-Emissionen Deutschlands entspricht.
Aufgrund der Vielseitigkeit der einzelnen Branchen und Wärmeanwendungen im Industriesektor kann dieser Beitrag nur beispielhaft einzelne Komponenten für eine Wärmewende aufzeigen, die auch wiederum die Aktivitäten der einzelnen Autoren widerspiegeln. Ausgehend von einer nationalen Betrachtung und expliziten Modellierungsergebnissen für die energieintensive Industrie in NRW, werden einzelne Potenziale und Aktivitäten im Bereich der Wärmebereitstellung, -speicherung und -integration behandelt.
The reduction of greenhouse gas (GHG) emissions by energyintensive industries to a net zero level is a very ambitious and complex but still feasible challenge, as recent studies show for the EU level. "Industrial Transformation 2050" by Material Economics (2019) is of particular relevance, as it shows how GHG-neutrality can be achieved in Europe for the sectors chemicals (plastics and ammonia), steel and cement, based on three main decarbonisation strategies. The study determines the resulting total demands for renewable electricity, hydrogen and for the capture and storage of CO2 (CCS). However, it analyses neither the regional demand patterns that are essential for the required infrastructure nor the needed infrastructure itself.
Against this background the present paper determines the regional distribution of the resulting additional demands for electricity, hydrogen and CCS in Europe in the case that the two most energy and CCS intensive decarbonisation strategies of the study above will be realised for the existing industry structure. It explores the future infrastructure needs and identifies and qualitatively assesses different infrastructure solutions for the largest industrial cluster in Europe, i.e. the triangle between Antwerp, Rotterdam and Rhine-Ruhr. In addition, the two industrial regions of Southern France and Poland are also roughly examined.
The paper shows that the increase in demand resulting from a green transformation of industry will require substantial adaptation and expansion of existing infrastructures. These have not yet been the subject of infrastructure planning. In particular, the strong regional concentration of additional industrial demand in clusters (hot spots) must be taken into account. Due to their distance from the high-yield but remote renewable power generation potentials (sweet spots), these clusters further increase the infrastructural challenges. This is also true for the more dispersed cement production sites in relation to the remote CO2 storage facilities. The existing infrastructure plans should therefore be immediately expanded to include decarbonisation strategies of the industrial sector.