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Page 1: Industrial Value Chain A Bridge Towards a Carbon …(cement stone) product can be used as filler in concrete with binding capacities, filler in cement with binding capacities, added

7 September 2018

Industrial Value Chain

A Bridge Towards a Carbon Neutral

Europe

ADDENDA

Page 2: Industrial Value Chain A Bridge Towards a Carbon …(cement stone) product can be used as filler in concrete with binding capacities, filler in cement with binding capacities, added

Sectors Technology Type Description TRL (current) Abatement potential CAPEX OPEX (compared to current) Energy Needs Source

Post Combustion

CCS (Norcem)CCS

Post combustion CCS: Tail-end separation of CO2 from flue

gas by e.g. chemical absorption, adsorption, membranes or

Calcium Looping. A world-first project for CC within the

cement industry has been underway at Norcem's plant in

Brevik, since 2013. 4 technologies tested with good results.

The project and study are gov. funded and managed in

cooperation with ECRA

Aims at demonstrating

at TRL 7

Capture about 95% of total

emissions (including process

and fuel CO2 emissions).

Potential for partial negative

emission technology (NET)

when combined with

alternative fuel use containing

biomass in cement kilns (max.

10% of total emissions).

n.a.

50-100 EUR/t CO2

(production cost of cement up

to 3 times higher)

Very energy intensive

technology

https://ecra-online.org/fileadmin/ecra/media/ECRA-

CEMCAP_Workshop_2017/Posters/The_cement_i

ndustry_approach_to_carbon_capture_ECRA.pdf;

CSI/ECRA-Technology Papers 2017:

http://www.wbcsdcement.org/technology

Oxyfuel CCS

(Retznei and

Colleferro)

CCS

Oxyfuel clinker production procees integrating combustion

with pure oxygen instead of air in combination with flue gas

recirculation tosignificantly increase the CO2 concentration

above 80% for efficient purification in a CPU unit. Requires

process and design adaptations

Aims at demonstrating

at TRL 7

Capture about 95% of total

emissions (including process

and fuel CO2 emissions).

Potential for partial negative

emission technology (NET)

when combined with

alternative fuel use containing

biomass in cement kilns (max.

10% of total emissions).

n.a.

40-60 EUR/t CO2 (production

cost of cement up to 1.5

times higher)

n.a.

https://ecra-online.org/fileadmin/ecra/media/ECRA-

CEMCAP_Workshop_2017/Posters/The_cement_i

ndustry_approach_to_carbon_capture_ECRA.pdf;

CSI/ECRA-Technology Papers 2017:

http://www.wbcsdcement.org/technology

Calcium looping

CCS (Cleanker)CCS

Advancing the integrated calcium-looping process for CO2

capture in cement plants

Aims at demonstrating

at TRL 7

Capture about 95% of total

emissions (including process

and fuel CO2 emissions).

Potential for partial negative

emission technology (NET)

when combined with

alternative fuel use containing

biomass in cement kilns (max.

10% of total emissions).

n.a. n.a. n.a.http://www.cleanker.eu/the-project/project-

contents.html

Direct Separation

CCS (Leilac)CCS

Based on technology called Direct Separation, which aims to

enable the efficient capture of the unavoidable process

emissions from lime and cement production. Calix’s

technology re-engineers the existing process flows of a

traditional calciner, indirectly heating the limestone via a

special steel vessel. This unique system enables pure CO2 to

be captured as it is released from the limestone, as the

furnace exhaust gases are kept separate. It is also a solution

which requires no additional chemicals or processes, and

requires minimal changes to the conventional processes for

cement as it simply replaces the calciner.

5-6

Capture over 95% of process

emissions (which account for

60% of total emissions of

cement production) or 57%

reduction of total emissions

n.a.

Can be no-regret measure

due high efficiency and high

product quality

Not higher compared to current

productionhttps://www.project-leilac.eu

CSA-Belite cement Alternative

binder

Alternative binder (sulpho-aluminate belite). Less CaCO3

carbonated and oven temperature 200˚C lower compared to

Portland cement clinker.

TRL 920-30%

(compared to CEM I)n.a.

CSI/ECRA-Technology Papers 2017:

http://www.wbcsdcement.org/technology; CE Delft

(2013). Update prioritering

handelingsperspectieven Verduurzaming

betonketen 2016.

Alternative CSHAlternative

binder

Alternative binder (alternative CSH cement). Ca-Si/CSH

similar to cement clinker but production process is (radically)

different. Works with autoclave (pressure) and lower

temperature.

TRL 4-550%

(compared to CEM I)n.a.

CSI/ECRA-Technology Papers 2017:

http://www.wbcsdcement.org/technology; CE Delft

(2013). Update prioritering

handelingsperspectieven Verduurzaming

betonketen 2016.

Calcinated clayAlternative

binder

Alternative binder based on calcinated clay and limestone.

Reduced clinker conted with up to 50%. Strength largely

dependent on calcinated kaolinite content.

n.a.30%

(compared to Portland cement)n.a.

CSI/ECRA-Technology Papers 2017:

http://www.wbcsdcement.org/technology; Scrivener

et al., 2018

Supersulphated

cement

Alternative

binder

Alternative binder (supersulphated cement). Consists of

granulated blast furnace slage, gypsum and (limited amount

of) cement clinker.

TRL 990-95%

(compared to CEM I)n.a.

CSI/ECRA-Technology Papers 2017:

http://www.wbcsdcement.org/technology; CE Delft

(2013). Update prioritering

handelingsperspectieven Verduurzaming

betonketen 2016.

Cements based on

carbonation of

calciumsilicates

(e.g. Solidia)

Alternative

binder - CCU

Alternative binder (CO2-activated cement) based on CaSiO3,

with sand and marl as main ingredients. During the

cement/concrete setting reaction, CO2 from the air is

captured. Around 300kg CO2 can be captured as such per

tonne of Solidia cement. The binder reduces emissions in two

ways: a) it replaces Portland cement b) it reacts with CO2 in

the air during the setting process. Solidia should be able to

replace fly ash and GBFS in cement.

TRL 8-960%

(compared to Portland cement)n.a.

CSI/ECRA-Technology Papers 2017:

http://www.wbcsdcement.org/technology; CE Delft

(2013). Update prioritering

handelingsperspectieven Verduurzaming

betonketen 2016.

TechnologiesC

emen

t

Equal than CEM I. 0 EUR/t CO2

High CAPEX (new investments) but much lower OPEX.

Replacement cost of existing clinker production plant is

lower. Estimated at 0 EUR/t CO2

n.a.

At least equal to CEM I, 0 EUR/t CO2

Negative costs. CEM I price at 82-87 EUR/t. Solidia

estimated at 46 EUR/t. Mitigation costs are -86 to -100

EUR/t CO2.

Page 3: Industrial Value Chain A Bridge Towards a Carbon …(cement stone) product can be used as filler in concrete with binding capacities, filler in cement with binding capacities, added

Alternative binded

from carbonation of

steel slag

(Carbstone/

Carbinox

(Registered

Trademark))

Alternative

binder - CCU

Alternative binder (CO2-activated cement), which can be

used as a replacement of Portland cement. During the setting

process, the carbstone binder reacts with CO2 in the air

(carbonation). The main input material is steel slag (from

BOF), which needs to be crushed and cleaned to remove

heavy metals. The milled slag is mixed with water and put in

an oven (80-140C for carbonation). For one m3 carbonstone,

around 2 tonne steel slag is required. Around 300 kg CO2

can be captured per m3 carbstone.

TRL 7-9

Twofold mitigation impact:

Replacement of clinker and

carbonation during production

process.

Net negative emissions due to

absorbtion of CO2 (-0,15 to -

0,20 tonnes CO2 per m3

carbstone concrete)

(compared to concrete 0,155

tonnes CO2/m3 concrete)

n.a.

CSI/ECRA-Technology Papers 2017:

http://www.wbcsdcement.org/technology; CE Delft

(2013). Update prioritering

handelingsperspectieven Verduurzaming

betonketen 2016.

Geopolymers/ Alkali

activated

Alternative

binder

Alternative binders (alkaline-activated materials), such as fly-

ash from coal fired power plants, granulated blast furnace

slag and alkali activator.

TRL 9min. 70-80%

(compared to CEM I)n.a.

CSI/ECRA-Technology Papers 2017:

http://www.wbcsdcement.org/technology; CE Delft

(2013). Update prioritering

handelingsperspectieven Verduurzaming

betonketen 2016.

Improved aggregate

packing

Materials

Efficiency

Optimization of aggregate packing. Denser packing of

aggregates will lead to lower requirement of binding agent.

Notably, next to size, also shape and texture are important in

aggregate packing.

TRL 4-9

20-40% less cement in

concrete for non-constructive

purposes;

0-5% less cement for

constructive concrete

n.a.

CE Delft (2013). Update prioritering

handelingsperspectieven Verduurzaming

betonketen 2016.

Mechanical cement

recycling

(Smartcrusher)

Materials

Efficiency

Mechanical cement recycling via C2CA or ‘smart crushing’.

This mechanical treatement of used concrete enables the

extraction of sand, aggregates and cement stone. The

(cement stone) product can be used as filler in concrete with

binding capacities, filler in cement with binding capacities,

added to the production process of Portland cement (lowering

the process emissions).

TRL 5-7 n.a. n.a.

CE Delft (2013). Update prioritering

handelingsperspectieven Verduurzaming

betonketen 2016.

Thermal cement

recycling

Materials

Efficiency

Based on ‘circular construction’ concept. Cleaned and broken

up concrete is heated to 650-700˚C. The process facilitates

further processing of recycling concrete. When reused it can

replace 10-20% Portland cement (half as efficient binding

agent as fly-ash).

TRL 417,5-32,5%

(compared to CEM I)n.a.

CE Delft (2013). Update prioritering

handelingsperspectieven Verduurzaming

betonketen 2016.

Mineral CO2 CCU

Use of filler in which CO2 is sequestered in this case

replacement of sand in concrete. The mitigation in principle

uses Olivine minerals which react with CO2. Olivine is

crushed finely to increase reacting surface with CO2 (under

pressure).

TRL 440-60 kg CO2 can be captured

like this per m3 of concrete. n.a.

CE Delft (2013). Update prioritering

handelingsperspectieven Verduurzaming

betonketen 2016.

Accelerated

Carbonation

Technology (ACT)

(Carbon 8)

CCU

Gravel substitute based on fly ash and/or bottom ash and

CO2. Based on chemical reaction of CO2 with fly ash. Per

tonne aggregrate, 45-55 kg CO2 is used (but lower because

purifying and concentrating CO2 stream requires energy).

TRL 5 (for waste

incinerator ash) - TRL 9

(for fly ash)

n.a. n.a.

CE Delft (2013). Update prioritering

handelingsperspectieven Verduurzaming

betonketen 2016.

Advanced grinding

technologiesEnergy Efficiency

Advanced grinding technologies could decrease the

electricity intensity of cement production beyond current best

practice levels and provide means to manage more flexibly

electricity demand. E.g. contact-free grinding systems,

ultrasonic-comminution, high voltage power pulse

fragmentation, low temperature comminution

A number of higher

efficiency grinding

technologies are

currently at TRL 6 while

others are in earlier

stages of development

Related CO2 reductions would

be dependent on the CO2

intensity of different electricity

grids

n.a. n.a. n.a.

CSI/ECRA-Technology Papers 2017:

http://www.wbcsdcement.org/technology; IEA

Tracking Clean Energy Progress 2017  (2018)

3D printing applied

in cement

construction

Materials

Efficiency

Additive manufacturing processes such as 3D printing have

the potential to considerably reduce the quantity of concrete,

and in some cases cement, during construction processes.

However, some digital fabrication processes use high

strength concretes that use considerably higher than normal

quantities of cement per unit of concrete, and thus

consideration should be given to whether a particular

application of digital fabrication actually reduces cement use

on net.

TRL 6-7 n.a. n.a. n.a. n.a. IEA Tracking Clean Energy Progress 2017 (2018)

Mitigation costs are (negative) -131 EUR to -261 EUR/t

Between 86 and 152 EUR/ton CO2

Low. Same cost as other aggregates. 0 EUR/t CO2

Cem

ent

Similar cost to regular concrete, so no additional costs

expected. 0 EUR/t CO2

20% cheaper compared to CEM I

-49 to -43 EUR/t CO2

0-2 EUR/t CO2

Page 4: Industrial Value Chain A Bridge Towards a Carbon …(cement stone) product can be used as filler in concrete with binding capacities, filler in cement with binding capacities, added

Electrification of

Tunnel KilnsElectrification

Electrification of kilns using low-carbon electricity could be an

option to reduce fuel emissions, particularly for large kilns

making bricks, roof tiles, wall and floor tiles. However this

option is not currently economically-viable due to the

significantly higher cost of electrical power compared to

natural gas. 

TRL 6-8

Based on an analysis of

current identified future

technologies and assuming

that all barriers regarding

alternative fuels are

overcomes, emission could be

reduced by up to 65% by 2050

compared with

1990 (this scenario does not

take into account kiln

electrification as it is not

considered economically

viable). Kiln electrification

could provide 78% emissions

reduction by 2050 compared

with 1990, when

assuming that half of all kilns

were are converted to electric

kilns in the period 2030-2050.

The

remainder are the unavoidable

process emissions. 

n.a. n.a. n.a.

Biogas and syngas Biomass

For high-temperature firing, replacing natural gas by biogas

or syngas, modifying existing kilns through retrofitting, is a

promising way to reduce fuel emission. However, biogas is

currently very expensive. On average, the kiln represent 80%

of the natural gas consumption of a clay production unit.

Substitution rates of up to 80% syngas could technically be

possible in some plants, with a potential reduction of running

costs.

TRL 6-8Could reduce emissions by

over 30%n.a. n.a. n.a.

Raw materials

development Energy Efficiency

The objective is to improve properties or reduce the peak

firing temperature/time, to enable reduction in energy and

CO2 emission, without compromising durability or other

technical performance requirements.

TRL 6-8 n.a. n.a. n.a. n.a.

Heat pump

technologyElectrification

Large heat pumps must be planned and configured

individually for their particular implementation area. For the

ceramic industry (in particular for bricks), heat pump drying to

replace the actual fossil based combustion-driven drying

technique.

TRL 3-6 57-73% n.a. n.a. could improve energy efficiency

by up to 80%

Hybrid-ring tunnel

kiln Electrification

Concept in which hybrid heating and networked production

and use of electricity yield significant cost.n.a. n.a. n.a. n.a.

Up to 65% savings on energy

are estimated

Large-Scale Electric

Kilns Electrification Electric kilns to substitute gas-fired kilns.  TRL 5-6  up to 80%  n.a.

Department for Energy and Climate Change and

the Department for Business, Energy and Skills

(2015). Industrial Decarbonisation & Energy

Efficiency Roadmaps to 2050 - Ceramic Sector

Appendices. P.62-70. Available at

https://assets.publishing.service.gov.uk/government

/uploads/system/uploads/attachment_data/file/4161

94/Ceramic_Appendices.pdf

Hybrid Kiln (Hybrid-

ring tunnel kiln with

flue-gas-based

combined heating

system is given as

example)

Electrification

Restructure of kiln to disband the thermal link between

kiln cooling and drying systems. Instead, use

of desulpherised kiln and dryer exhaust gases supplemented

with a gas-driven heat pump to maximise quantity of high-

quality thermal energy. This coupling allows choice between

electric heating (using CHP is an option) and primary fuel. 

TRL 1-4  n.a.  n.a.

Schaffer C. (2015). Hybrid-ring tunnel kiln flue-gas-

based combined heating system: 65% savings on

energy - a concept study. In Ziegelindustrie

International

Design for energy

efficient Kiln Energy Efficiency

Radically improved kiln architecture through the design of

innovative hardware furnace components (biofuel-fed CHP

unit, heat pipes and emissions abatement system), and major

developments in hardware-software kiln parts (kiln control

tool, refractory materials). 

TRL 4-6  n.a.  n.a. www.spire2030.eu/dream

Cer

amic

Cerame-Unie (sector input)

CAPEX €22.6m per site 

Optimisation of processes to reduce OPEX. For CAPEX,

innovation based around converting/supplementing existing

facilities. Approximate payback period of 2-3 years 

OPEX reduction of 20% and CAPEX reduction of 19% 

Page 5: Industrial Value Chain A Bridge Towards a Carbon …(cement stone) product can be used as filler in concrete with binding capacities, filler in cement with binding capacities, added

On-site CHP  Energy Efficiency

Concurrent production of electricity and thermal energy in an

integrated system. Heat that would have otherwise have

been lost can be used to supply demand directly.  Applied to

recover waste heat from the cooling stage of ceramic

production by channeling hot air from the drying stage to use

in the cogeneration system via a heat exchanger placed in

the cooling zone.

TRL 7-9 

± 0.7 M tons CO2 saved in the

Spanish wall & floor tile and

brick & roof tile sectorsxxviii 

Fuel consumption savings of

30%

Batier, R (2013). The Cogeneration in the EU

Ceramic Industry. Presentation for the Europe

Annual Conference 2013. Available at

http://www.cogeneurope.eu/medialibrary/2013/04/2

3/5358df6a/Renaud%20Batier%20-%20Cerame-

Unie.pdf

Heat recovery

technologies

(closed-loop heat

pump used as

example)

Energy EfficiencyTechnology to maximise heat recovery from kiln exhausts, kin

dryers and from cooling zones e.g. heatpumps, ORC etc.  TRL 5- 7  57-73%   20-40% www.dry-f.eu/About

Biomass

GasificationBiomass

Application of biomass gasifiers to convert biomass into fuel

by gasification; to act as feedstock in replacement of fossil

fuels (LPG or natural gas) for thermal energy production 

TRL 5-629% (in heavy clays sub-

sector) n.a.

Department for Energy and Climate Change and

the Department for Business, Energy and Skills

(2015). Industrial Decarbonisation & Energy

Efficiency Roadmaps to 2050 - Ceramic Sector

Appendices. Available at

https://assets.publishing.service.gov.uk/government

/uploads/system/uploads/attachment_data/file/4161

94/Ceramic_Appendices.pdf 

CCS  CCS Capturing CO2 from exhaust gases to sequester  TRL 5-650% (in the heavy clays

subsector)

No savings in fuel consumption.

Added energy consumption for

CCS process [2]

1)Department for Energy and Climate Change and

the Department for Business, Energy and Skills

(2015). Industrial Decarbonisation & Energy

Efficiency Roadmaps to 2050 - Ceramic Sector

Appendices. Available at

https://assets.publishing.service.gov.uk/government

/uploads/system/uploads/attachment_data/file/4161

94/Ceramic_Appendices.pdf 

2)Department for Energy and Climate Change and

the Department for Business, Energy and Skills

(2015). Industrial Decarbonisation & Energy

Efficiency Roadmaps to 2050 – Ceramic Sector.

P.75. Available at

https://assets.publishing.service.gov.uk/government

/uploads/system/uploads/attachment_data/file/4166

76/Ceramic_Report.pdf 

3) Department for Business, Energy and Industrial

Strategy (UK) (2017). Ceramic Sector: Industrial

Decarbonisation and Energy Efficiency Roadmap

Action Plan. P.20. Available at

https://assets.publishing.service.gov.uk/government

/uploads/system/uploads/attachment_data/file/6512

29/ceramics-decarbonisation-action-plan.pdf

CCU   CCUCapturing CO2 from exhaust gases to use in other

processes  TRL 3-6 90% 75% [1]

1) www.ceramicaalta.com/life-technical-progress

2) Department for Business, Energy and Industrial

Strategy (UK) (2017). Ceramic Sector: Industrial

Decarbonisation and Energy Efficiency Roadmap

Action Plan. P.20. Available at

https://assets.publishing.service.gov.uk/government

/uploads/system/uploads/attachment_data/file/6512

29/ceramics-decarbonisation-action-plan.pdf

Cer

amic

Lower distribution costs, supplies 25% of

electricity needed internally in installationsxxx 

Reduce production costs by up to 20%/Kg 

CAPEX €17m per site 

CAPEX for CC technology is estimated to be €11.3m per site

(for the heavy clay subsector). No expected OPEX savings 

OPEX gains from end-of-pipe procedures that lower fuel

consumption, higher productivity and from ease to treat

exhaust gases with reduced carbon dioxide, nitrogen dioxide

and particulates

Page 6: Industrial Value Chain A Bridge Towards a Carbon …(cement stone) product can be used as filler in concrete with binding capacities, filler in cement with binding capacities, added

New

hydrometallurgical

process for purity

silicon production

for use in silicon

wafers

energy Efficiency n.a. n.a.

75% less energy as compared

to the traditional process

technology

(gasificationprocess)

process)."

n.a. n.a. n.a. n.a.

Enhanced use of

natural gas

Switch to natural gas for ferro-alloy manufacturing in order to

lower emissions: it is a cleaner source of energy and

reducing agent, compared to solid carbonaceous materials

such as coal and metallurgical coke. This possibility is also

investigated due to the possible shortage of high-quality fossil

carbon materials and charcoal in the future. 

TRL 2-5 n.a. n.a. n.a. n.a. n.a.

New Ferro-chrome-

nickel process

Innovative ferro-chrome-nickel process to improve stainless

steel value chain: Approximately two thirds of annual nickel

production is used as a raw material in the making of

stainless steel, and about 60% of these nickel products are in

the form of metallic nickel such as nickel cathode or

briquettes. In the stainless steel production process nickel is

blended with iron- and chrome-based raw materials, and

metallic nickel is typically only required for final steel fine-

tuning. A new technology is developed to enhance the nickel

value chain for stainless steel producers. It would offer

multiple benefits compared to existing technologies such as:

a higher tolerance for impurities in the HPAL intermediate

product, avoiding the need for further nickel refining, and the

improved recovery of all metals in the FeCr process.

TRL 2-3 n.a. n.a. n.a. n.a. n.a.

Waste gas

fermentation to

biomass-biofuels

Projects to evaluate options for recovering energy from the

gases and reducing CO2 emissions: numerous technologies

are being considered. Among them, gas fermentation

technology to produce ethanol, biomass, and Omega-3 lipids

as an ingredient for the domestic fish food/aquaculture

market.

TRL 3-5 n.a. n.a. n.a. n.a. n.a.

Off-gas processing

Off-gas processing for the ferro-alloy industry which consists

of a combination of a traditional submerged arc furnace

combined with a dedicated combustion chamber for

controlled energy recovery.  The concept improves the

potential for high quality energy recovery, and opens to other

innovations in the process such as redesign of the furnace

itself for reduction of emissions such as tars, hydrocarbons.

 The conversion of today's waste streams, such as

dust/sludge from filter systems in ferromanganese systems,

into valuable products is facilitated. 

TRL 4-5 n.a. n.a. n.a. n.a. n.a.

Use of bio-carbon

The use of biocarbon has been studies for several years now.

For example, there is an on-going study on the quality of

charcoal from Eucalyptus clones for silicon production.

However the competition of many industries around this

material as well as the volume of biocarbon needed represent

major constraints.

TRL 2-5 n.a. n.a. n.a. n.a. n.a.

Industrial

Symbiosis

Industrial

Symbiosis

For Example: Heat recovery, e.g. steam power turbine re-

generating a large part of the company’s electricity input, e.g.

generating hot water for consumption by nearby community,

Carbon Capture and Use in Industry park, Carbon Capture

and Use for algae farming which produce biofuels, etc. 

n.a. n.a. n.a. n.a. n.a. n.a.

Ferr

o-A

lloys

& S

ilico

n

Page 7: Industrial Value Chain A Bridge Towards a Carbon …(cement stone) product can be used as filler in concrete with binding capacities, filler in cement with binding capacities, added

Increased use of

recycled container

glass TRL 9

Max 20% n.a. n.a. n.a. Glass Alliance Europe (sector input)

Increased use of

recycled glass (flat)

TRL 9

Max 5% n.a. n.a. n.a. Glass Alliance Europe (sector input)

Use of waste heat to

pre-heat raw

materials (standard

batch or pelletised

batch)

Energy Efficiency

Waste heat can be used to preheat the raw materials

entering the furnace. Currently this is limited to preheating of

either cullet only or batches containing more than 40% cullet,

otherwise clogging problems and dust carry-over would

occur. This is why the necessity to increase the availability

and affordability of good quality cullet (point above). The use

of pelletised batch would remove this limitation and solve the

issue of batch carry-over, which is often associated with the

use of pre-heaters but is not yet mature. It must be noted that

pre-heating raw materials cannot be coupled with electric

melting, as the flue gas temperature in this case is too low.

TRL 8 Max 15% n.a. n.a. n.a. Glass Alliance Europe (sector input)

Low carbon/hybrid

combustionBiomass, H2

This option includes switching to oxy-fuel combustion utilising

decarbonised electricity to produce the oxygen, use of biogas

and addition of carbon-free hydrogen to the gas grid.

However, any alternative fuel (especially hydrogen) must be

modified in such a way that the radiation from the flame is

effectively transferring energy to the glass. This will still

require quite some coordinated research. The efficiency of

oxyfuel combustion can be improved by preheating of the gas

and oxygen using the waste heat from the furnace.

TRL 8 Max 85% n.a. n.a. n.a. Glass Alliance Europe (sector input)

Electric melting electrification

A switch to all electric melting using decarbonised electricity

would eliminate CO2 emissions from glass melting which are

generated from the combustion of fossil fuels. It has to be

noted that process emissions (originating from the

decomposition of raw materials leading to CO2 emissions

and representing about 15% of the total glass industry’s

emissions) will not be eliminated by this technology. Although

electric melting is available for small furnaces (< 150 tpd), it

still needs to be demonstrated for large furnaces such as

those used in flat or container glass production (from 200 to

1.000 tpd). For certain glass compositions (e.g. E-glass for

reinforcement fibers) there are technical aspects (associated

with the electrical conductivity) which limit the proportion of

electrical energy for melting. Currently, there is no all-electric

furnace for melting E-glass. The cost of electricity and the

quality of melting (especially with high level of cullet) and final

glass products are the main barriers to uptake and further

innovation in this area. But the stability of the  grid and the

safety of electricity supply are also essential parameters to

consider for glass melting since glass furnaces need

permanent energy feed and cannot be turned on and off

depending on the availability of decarbonised electricity.

TRL 9 (small furnaces)

TRL 5 (large furnaces*)

* It must be noted that

the container glass and

flat glass industries

together represent over

85% of the EU glass

production and

emissions. They are

precisely the two

sectors with the largest-

size furnaces (from 200

to 1000 tonne of glass

per day).

Max 85% n.a. n.a. n.a. Glass Alliance Europe (sector input)

Gla

ss

Increased supply of

good quality cullet

Materials

Efficiency

Some container and flat glass manufacturers have the

potential to use more cullet (=recycled glass) on the condition

that it is available at the right quality. The utilization of cullet

saves energy and reduces the requirement for the use of

virgin raw materials, which release CO2 during the glass

melting process.

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New kiln

technologiesEnergy Efficiency

Options: Switching from horizontal to vertical kilns, installing

heat exchangers in horizontal kilns, Switching from vertical

kilns to vertical kilns PFRK, Improved use of waste heat,

Energy recovery in hydration, Efficient insulation lining to

minimize the shell heat losses, Optimal combustion process,

Improved processed and input control.

n.a. n.a. n.a. n.a. n.a.

Use of syngas

Fuel switching -

materials

efficiency

Ecoloop – Ecological looping. Ecoloop aims at producing

pure syngas without any flue gas emissions. The gas is

produced from shredded material from the automobile

industry, sorting residues and rubber parts that have not been

pre-processed. Lime is added as the transport medium,

pollutant-bonding material and catalyst. After purification the

gas is directly available for thermal or material utilization or

electricity production. The syngas can also be used instead of

natural gas in the lime productions and improves the quality

of lime.

TRL 4, As example

please see ECOLOOP

project

n.a. n.a. n.a. n.a.

Changes in fuel mix Fuel switching

Options: Use of gas instead of solid fossil fuels,

Use of waste as a fuel

Use of biomass as fuel

Use of electricity to heat kilns

Solar heat

n.a.

For Use of gas instead of solid

fossil fuels if sufficient gas

supplies are available: If we

assume that the current 51%

energy use in the form of solid

fossil fuels would be replaced

by gas, the average emission

factor of the fuel mix would be

reduced by 28%..

n.a. n.a.

Use of gas instead of solid fossil

fuels

-lower gas price

-connect the lime plants to the

natural gas grid → investments

in the piping network. -

investments in burners

All fuels supplied by biomass

-more research to improve the

applicability of biomass

-Security of supplies

-Sustainable biomass (we

would need 6,000 Km2 to

produce biomass) -investments

in adapt injection and burners,

and pre-treatment -Competition

with other users of biomass

Use of electricity to heat kilns

-Lower power prices -extensive

R&D

Calcium carbonate

loopingCCS/CCU

Calcium Carbonate looping - a technology tested for low-cost

post combustion CO2 capture for fossil fuels using limestone

based solid sorbents.

As example please see

CARINA Carbon

Capture by Indirectly

Heated Carbonate

Looping Project; see

CaO2 Calcium

carbonate looping for

coal power plants

project; see SCARLET

Scale up of CCL

technology for efficient

CO2 Capture from

Power and Industrial

Plants TRL 6

n.a.

CO2 to fuels CCU

CO2 capture solution and biofuel production from CO2

Emissions from Lime production (direct use of algae) - Algae

culture and biomass production would allow for the CO2

capture of lime furnace fumes and the production of biofuels

that could be used within the furnaces during the production

process.

As example please see

AGICAL + project TRL

4

n.a.

Carbon capture

using limestoneCCS/CCU

CO2 capture solution using limestone - CO2 can be captured

from flue gases using limestone with a scrubber installation.

Limestone in combination with CO2 and water forms calcium-

hydrogen- carbonate, which can be released in rivers, lakes

and oceans. This has the added benefit eliminating the

problem of CO2 storage and functioning as an acidity buffer

in oceans.

As example please see

ECO Ecological CO2

scrubbing project TRL 5-

6

n.a.

Lim

e

EULA (sector input)

n.a. n.a. n.a.

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Carbon capture with

oxyfuel (and CO2

looping)

CCS/CCUCombination with oxyfuel process- Storage of renewable

energy by combination of Oxyfuel process with CO2 looping.

As example please see

Innovative CCU project

TRL 1-2

n.a.

Carbon capture

through

mineralisation

CCS/CCU

Carbon dioxide Storage by Mineralisation (CSM) - The

purpose of Carbon Storage by Mineralisation (CSM) is to

promote CO2 fixation by metal oxide into thermodynamically

stable carbonates while benefiting of the exothermicity of the

carbon reaction.

As example please see

CSM Carbon Storage

by Mineralisation TRL 6-

7

n.a.

Carbon capture with

oxyfiringCCS/CCU

Oxyfiring - With oxy-firing, oxygen is used instead of

conventional air for combustion in the lime production

process. As this eliminates the diluting N2 introduced with the

use of air, this facilitates the concentration of CO2 from the

flue gasses, at the expense of additional energy use to

produce the oxygen.

n.a. n.a.

Carbonation in

mortarsLime carbonation Carbonation in lime mortars TRL 7-8

For mortars, within 100 years

80-92% carbonation takes

place. As ±4% of lime used in

mortar and process emissions

currently form 67% of total

emissions associated with the

manufacture of lime, the

carbonation amounts to ±2%

of the emissions stemming

from the EU lime production.

n.a. n.a. n.a.

Direct Separation

CCS (Leilac)CCS/CCU

Based on technology called Direct Separation, which aims to

enable the efficient capture of the unavoidable process

emissions from lime and cement production. Calix’s

technology re-engineers the existing process flows of a

traditional calciner, indirectly heating the limestone via a

special steel vessel. This unique system enables pure CO2 to

be captured as it is released from the limestone, as the

furnace exhaust gases are kept separate. It is also a solution

which requires no additional chemicals or processes, and

requires minimal changes to the conventional processes for

cement as it simply replaces the calciner.

5-6 

[Innovation in the Lime

Sector 2.0 (2018) gives

a TRL of 7-8]

capture over 95% of process

emissions (which account for

60% of total emissions of

cement production) or 57%

reduction of total emissions

n.a.

Can be no-regret measure

due high efficiency and high

product quality

n.a.

Carbonation in soil

stabilizationLime carbonation Carbonation in soil stabilization  TRL 7-8 n.a. n.a. n.a. n.a.

Less Fines

Resource

efficiency/

circular economy

The aim of the project is to reduce the amount of lost material

(material < 10mm to 20mm and too fine to use) by 50%

through the adaptation of the explosives and timing

procedure to the natural breakage characteristic of the rock. 

TRL 6-8 n.a. n.a.Reduced operating costs and

increased outputn.a. EULA Innovation in the Lime Sector 2.0 (2018)

Repurpose lime by-

products

Resource

efficiency

Optimisation of waste and by-products e.g. use of filter

sands minerals (a by-product) in lime-fertiliser or to be used

in earth and environmental construction 

TRL 8-9 - n.a. n.a. n.a. EULA Innovation in the Lime Sector 2.0 (2018)

Gravity conveyer

belt

Energy

generation &

efficiency

Investment to refit, boost and optimize the operations of the

site: two new crushers, two shafts, and an underground

tunnel for a gravity conveyer belt. 

TRL 8-9

The conveyor belt, working

with gravity, about 200 MWh

per year of electricity can be

generated. More than 150 tons

of CO2 can be saved per year,

n.a. n.a. n.a. EULA Innovation in the Lime Sector 2.0 (2018)

Nordalk (Austria)Resource

optimisation

Nordkalk strives to optimize use of all extracted /processed

raw materials. Using all byproducts: wall rock that is extracted

in addition to regular limestone, fine sand produced in the

flotation process, filter dust, which builds up in all lime kilns

and at grinding plants, and residues created in lime burning

and slaking. Also assists customers by handling their process

byproducts in a sustainable way.

TRL 8-9 n.a. n.a. n.a. n.a. EULA Innovation in the Lime Sector 2.0 (2018)

Lim

e

EULA (sector input)

n.a. n.a. n.a.

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BIOXYSORB -

Biomass co-

combustion under

both air- and oxy-

fuel conditions

Energy efficiency

Objectives: Assess experimentally and technoecono­mically

of 1st and 2nd generation biomass co-combustion under both

air and oxyfuel conditions at various co-combustion ratios in

combination with flexible, low cost SOx, HCl and Hg emission

control by sorbent injection. Economic low carbon power

production and emissions control for future and flexible

biomass cofired power stations

TRL 6-7 n.a. n.a. n.a. n.a. EULA Innovation in the Lime Sector 2.0 (2018)

CaO2- Calcium

carbonate looping

for coal power plant

Carbon

sequestration

Process optimisation of the CO2 capture post combustion

calcium looping system for coal based power plants. This

process scheme is intended to minimize or even avoid the

need of a CO2 recycle to the oxyfired circulating fluidized bed

calciner, by exploiting the endothermic nature of the

calcination reaction and the large solid flow circulating from

the carbonator

TRL 6 n.a. n.a. n.a.

The standard CaL system can

re­duce about 20-30% the

energy requirements in the

calciner by switching to a

configuration as proposed in the

CaO2 project 

EULA Innovation in the Lime Sector 2.0 (2018)

CALENERGY Carbon looping Limestone based chemical looping combustion technology TRL 6-7 n.a. EULA Innovation in the Lime Sector 2.0 (2018)

ECO2 -

Economical CO2

scrubbing

CCUConstruction of a pilot plant with a cascaded scrubber system

to remove CO2 with limestone powder and produce ready to

use buffered water. 

TRL 7 n.a. n.a. n.a. n.a. EULA Innovation in the Lime Sector 2.0 (2018)

CO2LOOP 4

ENERGY STORAGE

Storage of RE/

CCU

First step: Use of renewable energy to operate electrolysis

through the production of O2 and H2 is used in a small scale.

Second step: Operation of shaft kiln with fossil fuels or

methane out of oxy fuel process. CO2 stripping is needed for

oxy fuel – synthesis as well as the assessment of the CO2 –

loop. The entire CO2 is concentrated in the loop of CO2 =>

pure CO2 in the exhaust gas. And the use of CO2 as coolant

of the solids in process. Potential for optimization of CCU

Process is identified. CO2 from the shaftkiln process (e.g.

limeproduction) is used to synthesize methane with the

hydrogen from the electrolysis. Support needed for

development/testing of process. Scale up of hydrogen

electrolysis / recuperator / test of CO2loop in shaft kiln and

optimization of the entire process chain.

TRL 1-2 n.a. n.a. n.a. n.a. EULA Innovation in the Lime Sector 2.0 (2018)

NECAPOGEN 4

LIME

Negative

emissions

technology

NEgative-CAarbon emission POwer GENeration from

integrated solid-oxide fuel cell and lime calciner. Origen

Power’s ‘negative emissions technology’ supplies natural gas

to a solid oxide fuel cell. About half the chemical energy is

converted into electricity and the remainder into highgrade

heat which is used to thermally decompose limestone

(CaCO3) in a calciner to produce) lime (CaO) and carbon

dioxide.

TRL 4-5 n.a. n.a. EULA Innovation in the Lime Sector 2.0 (2018)

ADIREN4LIME -

Anaerobic

Digestion as RE

Energy efficiencyProject finalized in 2015. Birch Energy financed, managed,

operates the AD installation in a restored area of the former

quarry operations.

TRL 8-9 n.a. n.a. n.a.

Uses 45,000 tonnes of

feedstock annually. Combined

output of the 3 AD plants is

110% of Singleton Birch’s

electricity demand. Grid

connection with capacity to

export 100% of electricity to grid

and generates 15,000 GWhrs of

electricity per annum

EULA Innovation in the Lime Sector 2.0 (2018)

WHEATREC4PG -

 Waste Heat

Recovery for Power

Generation

Energy Efficiency

Feasibility study of a Heat recovery system installation in lime

operations: integrate organic rankine cycle (ORC) technology

into renewable heat sources, industrial kilns and furnaces.

The ERC generator can convert waste heat temperatures as

low as 85°C into electricity. Waste heat from heat intensive

industrial processes can be recovered by: 1. High

temperature hot water above 85°C. 2. Saturated steam

above 6 bar. 3. Exhaust gas above 130°C. These sources of

waste heat are fitted with a heat exchanger designed for the

application.

TRL 8-9

kiln CO2 emissions will be

reduced by 1,600 tonnes per

year.

The project offers an

attractive return on

investment, when considering

£1.3m investment against

purchasing 3,000 MWh per

year of electricity from the grid

over the next 10 years

n.a. n.a. EULA Innovation in the Lime Sector 2.0 (2018)

If the electricity and the lime are sold at wholesale market

prices, then the costs are covered without a carbon price –

even as it removes carbon dioxide from the air.

Lim

e

The low cost limestone oxygen carrier along with less

expensive more efficient reactors drives down capital and

operating costs rela­tive to conventional systems. 

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High Temperature

electrificationElectrification High-temperature heat processes via electricifation

Available in <10 years

[TRL 5-7]n.a. n.a. n.a. n.a. n.a.

Further

electrification in

nickel production

ElectrificationIn the nickel industry, various sources of fossil fuels are used

in the production of technical/industrial gases which might be

replaced by electricity (longer-term). 

Available in <10 years

[TRL 5-7]n.a.

Use of biomass to

heat furnacesBiomass

In Silicon production furnaces can operate with

a relatively high biocarbon content. Some installations

already use some biocarbon, but there remain bottlenecks

(i.e. technology, cost)

Available in >10 years

[TRL 2-4]n.a.

low carbon fuels in

copper productionFuel switching

There is potential for low-carbon fuels to replace fossil fuels

in copper production, once economically competitive and

available insufficient quality. 

Available in >10 years

[TRL 2-4]n.a.

Use of biofuels in

nickel productionBiomass

There is potential for biofuels to replace fossil carbon in

various stages of nickel production, once economically

available competitive and available at a sufficient quality

Available in >10 years

[TRL 2-4]n.a.

Electrification

and/or H2 use in

zink production

Electrification -

H2

Hydrogen combustion or electric heating can be considered

as a replacement to fossil fuel used for heating purposes in

the hydrometallurical process of zink production, and

coke as the reductant and combustible in the

pyrometallurgicalprocess (when cost-effective, and once

safety challenges are overcome).

Available in >10 years

[TRL 2-4]n.a.

Reuse of surplus

heatEnergy Efficiency

Further optimisation of surplus heat utilisation is possible,

where geographical and economic conditions   allow it. As

well as reducing a company’s direct emissions, there is great

potential for using surplus heat for local district  heating

to reduce wider societal carbon emissions (i.e. Aurubis is

providing heat to a Hamburg district).

Available in <10 years

[TRL 5-7]n.a.

CCS/CCU CCS/CCU

New CCS/CCU technologies are a potential breakthrough

technology, but challenges must be overcome. It is realistic to

assume that these technologies would first be developed and

commercialised by larger carbon-intensive industries. One

example: Finnfjord’s Norway silicon production plant is using

recovered CO2 to farm algae and then produce biofuels.

Available in >10 years

[TRL 2-4]n.a.

Efficiency

improvements

related to electricity

use

Energy Efficiency

Incremental technology for primary is making important

progress in Europe through one of the recent pilot projects

located in Karmoy, Norway. Still in pilot stage, this is the

ultimate technology to reduce electricity consumption with

carbon anodes.

TRL 7

15%, per tonne of aluminium,

compared to current global

average figures. assuming that

it is integrated in all the 26

existing smelters operating in

Europe (4,2 million tonnes per

year)4: this replacement could

eventually have a reduction of

almost 10 TWh/y in Europe

as each smelter has its own

specific configuration, the

integration of this new

technology would require

investment costs in existing

plants replacing existing

technology, and the actual

retrofitability would have to be

assessed on a case-by-case

n.a. n.a. EEA (sector input)

Bio-anodesMaterials

Efficiency

Use of biomass as raw material in anode production – bio-

anodes

Available in <10 years

[TRL 5-7]n.a. n.a. n.a. n.a. EEA (sector input)

Wetted anodes Energy Efficiency

Using cathodes made from wetted materials, such as titanium

diboride, would improve the electrical contact between molten

aluminium and the cathode and in turn allow for a decreased

anode-cathode distance without causing difficulties for the

smelting process.

TRL 5-6 n.a. n.a. n.a.

Wetted cathodes could reduce

energy use by approximately

20% compared to conventional

carbon cathodes

IEA Tracking Clean Energy Progress 2017 (2018)

Multipolar cells Energy Efficiency

While conventional Hall-Héroult cells have a single-pole

arrangements, multipolar cells could be produced by using

bipolar electrodes or having multiple anode-cathode pairs in

the same cell.

TRL 6

Since the cells require inert

anodes, process emissions

from the use of carbon anodes

would also be reduced

n.a. n.a.

potential to reduce energy

consumption by 40%, due to

lower operating temperatures

and higher current densities

IEA Tracking Clean Energy Progress 2017 (2018)

Novel design of anodesEnergy Efficiency

The physical design of anodes can be altered to improve

energy efficiency of Hall-Héroult cells. For example, sloped

and perforated anodes make electrolysis more efficient by

allowing better circulation within the electrolyte bath, while

vertical electrode cells save energy by reducing heat loss and

improving electrical conductivity.

n.a n.a. n.a. n.a.

Energy savings can be

considerable, with one source

estimating slotted anodes can

reduce energy by 2 to 2.5 kWh

per kg of aluminium

IEA Tracking Clean Energy Progress 2017 (2018)

No

n-fe

rro

us m

etal

s

n.a. n.a. n.a. Eurometaux (sector input)

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Electrolysis demand response

Industrial Symbiosis

TRIMET is currently operating an industrial scale pilot of the

EnPot demand response technology in 120 furnaces at its

Essen, Germany location. The total 'storage' capacity of the

pilot project is 1,120 MWh, and has a 95% efficiency level.

TRL 7-8 n.a. n.a. n.a.

The technology could enable an

aluminium smelter to increase

or decrease its electricity

consumption by 25% for up to

several hours at a given time,

without adverse impacts on the

production process. Thus, the

smelter could increase power

consumption at times when

demand and prices are low,

effectively 'storing' electricity in

molten aluminium so that

electricity consumption can be

reduced at times of high

demand and prices. This would

help with managing supply and

demand variability in the power

sector, which will become

increasingly important as higher

shares of variable renewable

energy are added to the grid

IEA Tracking Clean Energy Progress 2017 (2018)

New physical recycling technologies

Materials Efficiency

New techniques for physically sorting scrap metal include

fluidized bed sink float technology, colour sorting, and laser

induced breakdown spectroscopy (LIBS)

TRL 5- 7  n.a. n.a. n.a.

reduce energy use in secondary

aluminium production by 12%,

relative to current methods of

secondary production.

IEA Tracking Clean Energy Progress 2017 (2018)

Integrated Process

managementEnergy Efficiency

This includes new pulping processes/techniques – such as

the use of Deep Eutectic Solvent (DES), water removal

techniques … (see also Deep Eutectic Solvents below).

TRL 4-7, depending on

the technologies. b.

Timeframe: from 2030

onwards

Fuel switching

(electricifation and

biomass

gasification)

Electrification

and Biomass

This includes full integration of power production and drying

processes, gasification of biomass, full electrification of the

paper-making process…

TRL levels: 3-10. In

some cases

technologies are

already commercially

available. In others, e.g.

electrification, a full re-

design of paper mills is

required. b. Timeframe:

it will depend on long-

term energy commodity

prices evolutions. In any

case, new electro-

technologies will be

deployed after 2030

Recycling/reuse

(circularity) beyond

current practices.

Materials

Efficiency

This includes new recycling technologies without wetting and

drying, upgrading (up-cycling) recovered fibres, urban

biorefineries…

TRL levels: 1-8.

Timeframe: from 2025

onwards

Valorisation of

pulp/paper making

waste streams

Materials

Efficiency

This includes valorisation of waste, waste water and sludges;

reduced dewatering and drying needs; improving dewatering

retention; light weighting …

TRL levels: 7-

8.Timeframe: from 2025

onwards

Bio-based

chemicals

Materials

Efficiency/Industr

ial symbiosis

This includes using components of wood - lignin, cellulose

and hemicellulose – as bio-based materials to replace

existing fossil and non-renewable ones.

TRL levels: 7-8.

Timeframe: from 2025

onwards

No

n-fe

rro

us m

etal

sP

ulp

& P

aper

CO2 abatement potential over

the period 2015-2050:

o Energy Efficiency: 7 Mt

o Fuel Switch: 8 Mt

o Demand-side Flexibility: 2

Mt

o Emerging & Breakthrough

tech: 5 Mt

- Production projections: from

105 Mt in 2015 to 113 Mt in

2050

Additional investment costs,

assuming current rate of

investments continue

(~€1bn/y):

- €24 billion cumulative

investments for direct

emissions reduction between

2015 and 2050

- €20 billion cumulative

investments for the

production of new bio-based

low-carbon products

(biochemical, biocomposites

and nanomaterials…)

n.a.

Future needs will depend on the

combination of:

- Deployment of energy

efficiency and emerging &

breakthrough technologies, that

will determine the total amount

of energy needed, and

- Evolution of energy prices

commodities, which will

determine fuel switching rates.

From a technical perspective,

the whole sector could be

potentially electrified, if this

option would be cost-

competitive.

Alternative fuels to replace

natural gas, such as biogas or

hydrogen, could also be

possible, should these fuels be

cost-competitive and available

from existing/refurbished gas

pipelines.

Moreover, future uses of

biomass for higher added-value

products (bioeconomy) could

have different implications: it

might trigger higher demand for

biomass and/or trigger further

electrification of the paper

industry to replace bioenergy.

But the bioeconomy

implications on the overall

biomass demand have not been

quantified.

CEPI (sector input)

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Deep Eutectic

SolventsEnergy Efficiency

Plant based solvents that can be used to fractionate biomass

into its constituent parts - lignin, hemicellulose and cellulose -

to be further processed. 

TRL 5-6 20% n.a. CEPI Two Team Project

Flash Condensing

with SteamEnergy Efficiency

Blasting mostly dry, high-consistency fibres with agitated

steam into a forming zone where the combination of

condensing and steam expansion enables bonding.

TRL 1-3 50% n.a. CEPI Two Team Project

Use of Steam in the

Paper Drying

Process

Energy Efficiency

Full power of steam enables total recovery of thermal energy,

to be used in subsequent processes. In papermaking, steam

and heat-boosted forming and pressing take place within an

air-free paper machine.

TRl 1 - 3 50% n.a. CEPI Two Team Project

Dry-Pulp for Cure-

Formed PaperEnergy Efficiency

Two technologies that enable paper production without water:

1) DryPulp and 2) cure-forming. DryPulp, a high

concentration of fibres treated with a bio-based protective

layer and suspended in a viscous solution, is pressed during

cure-forming to remove the viscous solution, forming a thin

sheet.

TRL 1-2 55% n.a. CEPI Two Team Project

Supercritical CO2 Energy Efficiency

Liquid-like characteristics of scCO2 allow for substitution of

steam-heated cylinders with scCO2 in the "extraction drying"

process. With gas-like characteristics scCO2 has uses

removing contaminants, adhesives and mineral oils in the

recycling process.

TRL 1-3 45% n.a. CEPI Two Team Project

100% electricity Electrification

Transition to green energy through 1) use of electricity-based,

energy efficient tech in place of fossil fuel-based alternatives

and 2) development of capacity to store cheap surplus

energy from the grid- generated by renewable sources.

Involving replacement of gas-fired boilers with electric/hybrid

boilers and use of electro-thermal technologies in the drying

process.

No specific TRL

calculated as it is

based on a cluster of

technologies.

20-100% depending on

electricity mixn.a. CEPI Two Team Project

Black Liquor

recovery

Materials

Efficiency/Industr

ial symbiosis

Recovery and gasification of black liquor can be used to

generate energy in the form of steam and on-site electricity

(to be used in the pulping plant) or as feedstock in the

synthesis of liquid fuels and chemicals.

TRL 7-8 n.a. n.a. IEA Tracking Clean Energy Progress 2017 (2018)

Lignin extraction

Materials

Efficiency/Industr

ial symbiosis

Extraction of lignin from wood pulp can enable its use in new

industrial products, or as biofuel in boilers or lime kilns.TRL 5-8 n.a. n.a. IEA Tracking Clean Energy Progress 2017 (2018)

Pul

p &

Pap

erFunding for the PROVIDES project under H2020 with

additional support from industry. DES is expected to reduce

investment costs by 50%

Reduced OPEX due to reduced need for water and energy,

and from smaller production units which cost less per

capacity

Full application could reduce costs by 30%. Further cost

reductions from reduced paper weight, reduced water

handling and treatment costs. Reduced CAPEX as forming

and drying sections would be shorter, and faster production

speeds would increase machine output. Further savings in

raw materials and energy, as sheet stratification would

present opportunities for recycling.

Lower energy demand would reduce operating costs for the

entire manufacturing chain and due to simplification of the

process, losses would also be minimised. CAPEX would be

20 times less due to smaller production units.

Using scCO2 in extraction drying has the potential to reduce

energy costs by 10-20% and to reduce capital costs, through

lower infrastructure costs and boiler capacity. Using scCO2 to

enable upcycling could increase material efficiency at mill

level by 10%.

High CAPEX from investments in new machines and

because it is expensive to replace them before the end of

their lifetimes. Energy-savings could reduce OPEX by 8%.

n.a

n.a.

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Low CAPEX energy

efficiency

investments

Energy Efficiency

Continuous improvement: through implementation of a

combination of measures and projects involving some capital

expenditure. Examples include fouling mitigation, catalyst

improvements and hardware improvements such as new

motors, heat-exchangers, etc.

TRL 6-8. Progressive

uptake from now until

2040

High CAPEX energy

efficiency

investments

Energy Efficiency

Major capital projects: Larger efficiency improvements

reflecting changes to the technical configuration of individual

refineries (e.g. extensive revamps of existing facilities, new

process plants).

TRL 3-8. By 2040

Integration of

processesEnergy Efficiency Inter-unit heat integration

TRL 6-8. Progressive

uptake from now until

2040

Energy

management

systems

Energy EfficiencyEnergy Management Systems combining equipment (e.g.

energy measurement and control systems) with strategic

planning, organization and culture.

TRL 6-8. Progressive

uptake from now until

2040

Heat recovery

technologiesEnergy Efficiency

Increased recovery of refinery low-grade heat for export and

electricity productionTRL 3-6. 2025-2030

Recovery of lower

CO2 fuelsFuel switching Improved recovery of Hydrogen and LPG from fuel gas TRL 4-8. By 2040

Higher levels of

electrification of

machinery, general

operations

ElectrificationIncreased use of imported low-carbon electricity: Use of

electricity for general operations a/o rotating machines

TRL 8. As grid becomes

Decarbonized.

Progressive uptake

from now until 2050

Use of electric

heaterselectrification

Increased use of imported low-carbon electricity: Substitution

of fired heaters/boilers by electric heaters

TRL 4-8. As grid

becomes

Decarbonized.

Progressive uptake

from now until 2050

Production of

hydrogen

electricification/H

2

Increased use of imported low-carbon electricity:Production

of hydrogen with electrolysers using imported renewable

electricity.

TRL 4-6. As grid

becomes

Decarbonized.

Progressive uptake

from now until 2050

Carbon Capture CCS

Capture of a portion of the total CO2 emitted by

refineries.The potential role of a CCS scheme together with

steam reforming plants (SMR) to produce a low-carbon

intensity Hydrogen is explicitly explored.

TRL 6-7. Major

deployment in the 2030-

2050 timeframe

≈25%

Notes.

1. 2050 CO2 emissions vs

2030 Reference Scenario

2. It assumes that all previous

opportunites (described above)

are exercised)

Low carbon feedstocks

Biomass + efuels

Progressive integration of sustainable bio-feedstocks, power-

to-fuels and bio-blendstocks into the refinery. Negative

emissions could potentially be achieved when combined with

CCS.

TRL 3-7. 2020+

Depending on pathways

considered the abatement

potential (Direct emissions)

could be higher than 70%

(Direct + Indirect CO2

emissions) for maximum

estimated upake.

As a preliminary assessment

focused on some illustrative

pathways, the results of the

ongoing Concawe’s modelling

work show the following

potential needs by 2050:≈ From

5 (*) up to 20/50 times (**) vs

2030.

Notes.

(*) Preliminary estimate for bio-

feedstock pathways

(**) Preliminary estimate for

combined low carbon pathways:

bio-feedstock uptake + power-to-

liquid production (Imported

electricity + CO2)

Hybrit - Hydrogen

based metallurgyH2

HYBRIT is based on direct reduction of fossil free iron ore

pellets using hydrogen and renewable energy, which

generates water as a byproduct instead of carbon dioxide,

followed by a fossil free EAF-based crude steel production. A

pre-feasability study has been successfully completed, lab

scale study and construction of a pilot plant, representing the

complete fossil free process chain from ore to crude steel,

are ongoing.

TRL 4-595%

75% (Based on the Swedish

energy mix) Lower primary

energy demand from approx.

5200kWh to 600kWh per ton of

steel Higher electricity demand,

from approx. 200 kWh to 3500

kWh

Hybrit (2018). Official webpage. Available at:

http://www.hybritdevelopment.com/

SALCOS and

GrInHy - Hydrogen

based metallurgy

H2

SALCOS is based on the industrial direct reduction process

using in addition to natural gas flexible amounts of hydrogen,

produced by renewable energy to significantly reduce the

CO2 emissions short term for the steel production, because

of the used industrial processes.

The GrInHy-project operates the biggest high temperature

electrolyzer (HTE) in an industrial application. The HTE

enables the production of hydrogen with the highest electrical

efficiency by using waste heat.

GrInHy:

TRL 5-6

SALCOS:

TRL 7-9

SALCOS: 26-95% (-26% CO2

compared to current BF-BOF

production; -82% CO2 if

operated with 55% H2; -95%

CO2 if operated with 100%

H2).

n.a.

1 Salcos (2018). Official webpage. Available at:

https://salcos.salzgitter-ag.com/en/ and GrInHy

(2018). Official webpage. Available at:

http://www.green-industrial-hydrogen.com/home/

Capex of the integrated project is estimated to be around

€1.3 Bn for the realisation of stage 2 (one DRP, one EAF

and necassary electrolyzer capacity). SALCOS is a concept

for an integration of a hydrogen based DRP-EAF route into

an integrated steel mill to avoid CO2 emissions up to 95 % in

several steps.

Stee

l

The three actors have, together with the Swedish Energy

Agency (which will take about one third of the cost),

committed to invest €135,5 Mn in the pilot plant. Cost of

steel product expected to be 20-30% more expensive

Ref

inin

g

≈20%

Note. 2050 CO2 emissions vs

2030 Reference Scenario

≈25%

Notes.

1. 2050 CO2 emissions vs

2030 Reference Scenario

2. It assumes that Energy

Efficiency measures (above)

are exercised

The capex required to implement these technologies into the

2030 Reference Scenario (Oil & CCS case) has been

preliminary estimated at minimum 45,000 M€ for the whole

EU refining system (profitable projects across the whole EU

refining system).

This estimated cost only refers to the generic cost of the

different technologies and opportunities identified. The actual

cost of implementation would be determined by the specific

conditions of each individual asset.

The scenarios analysed will

require a different amount of

energy, alternative feedstocks

and infrastructure needs. As a

preliminary assessment focused

on some illustrative pathways,

the results of the ongoing

Concawe’s modelling work

show the following potential

needs by 2050:≈ Up to 85,000

GWh/y.

The preliminary capex estimate varies depending on the

combination of different low carbon feedstocks (availability)

and technologies considered (different pathways chosen by

individual refineries). This capex assumes the co-processing

or co-location of new conversion technologies within or close

to the refinery, maximizing the synergies and utilization of

the existing refining units.

As a first estimate based on Concawe’s preliminary

modelling work (potential future demand) complemented

with external references, the CAPEX required is about

600,000 M€

for maximum uptake .

Concawe:

- The - Low Carbon Pathways Project. A holistic

framework to explore the role of liquid fuels in

future EU low-emission mobility (2050).

- Low Carbon Pathways CO2 efficiency in the EU

Refining System. 2030 / 2050 – Executive

Summary (Interim report)

FuelsEurope:

https://www.fuelseurope.eu/wp-

content/uploads/2018/04/DEF_EN_FE_Vision2050

_digital.pdf

Clingendaelenergy

http://www.clingendaelenergy.com/inc/upload/files/

CIEP_Paper_2018-_01_Web_beveiligd.pdf

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Methane pyrolysis

by BASF/Linde H2

BASF (chemicals), the Linde Group (chemicals) and

ThyssenKrupp (steel) are developing a technology for

hydrogen production through methane pyrolysis, where

natural gas is processed under high-temperature to obtain

hydrogen and carbon.

TRL 1 - 3

50% (Approx. 50% reduction in

the hydrogen production

process compared to steam

methane reforming

SALCOS: Assuming operation

with 55% H2, additional

renewable electrical power

demand amounts to 12.43

TWh/year and additional natural

gas demand ~23 PJ/year. This

equals approx. 6.9% renewable

generation and approx. 0.8%

natural gas consumption in

Germany 2016). GrInHY:

(Electricity demand of around

40kWh/kg. Electrical efficiency

during power production

designed for 50%

The Linde Group (2015). Linde develops a new

production process for synthesis gas. Available at:

https://www.the-linde-

group.com/en/news_and_media/press_releases/ne

ws_20151015.html

H2Steel including

SUSTEEL and H2

future - Hydrogen

based metallurgy

H2

The SUSTEEL technology is based on the idea of hydrogen-

based DRI-EAF steelmaking, yet, combines both processes,

DRI production and EAF steelmaking, into one single

process. (Hydrogen Plasma Smelting Reduction: HPSR

process), and uses the H2 Future hydrogen technology. H2

Future aims at full scale demonstration of hydrogen

production through PEM electrolysis. Further H2Steel project

activities will focus on the technological development,

upscaling and integration of these processes.

H2 Future:

TRL 6-7

SUSTEEL

TRL 4-5

SUSTEEL: (The consortium

has chosen not publish any

emission reduction values, and

are currently computing

predictions that will be ready

forpublication within 1-2

years

n.a.

SUSTEEL: Voestalpine (2018). The three pillars of

decarbonization. Available at:

https://www.voestalpine.com/blog/en/innovation-

en/the-three-pillars-of-decarbonization.

H2 future: H2-Future (2018). Official website.

Available at: https://www.h2future-project.eu/

Sector input

Carbon4PUR CCU

Based on transformation of the flue gas streams (containing

CO2/CO) from the energy-intensive industries into higher

value intermediates for market-oriented consumer

products.[1]

TRL 2-4

20-60%

[Secondary reduction]

(20-60% reduction in carbon

footprint of PUR intermediates

compared to today’s crude-oil

based production) [2]

70%

(70% reduction of process

energy in the polyol producing

industry, including 15-36%

reduction of petrochemical

epoxy compounds) [2]

1) Carbon4PUR (2018a). Official webpage.

Available at: http://www.carbon4pur.eu/.

Cordis - Carbon4PUR (2018). Turning industrial

waste gases (mixed CO/CO2 streams) into

intermediates for polyurethane plastics for rigid

foams/building insulation and coatings. Available at:

https://cordis.europa.eu/project/rcn/211464_de.html

2) Carbon4PUR (2018b). Flyer. Available at:

https://www.carbon4pur.eu/wp-

content/uploads/2018/05/Carbon4PUR-Flyer.pdf 

3)CORDIS – SPIRE 08.2017 (2017). Carbon

dioxide utilisation to produce added value

chemicals. Available at:

https://cordis.europa.eu/programme/rcn/701834_en

.html 

Steelanol CCUSteelanol is making industrial waste gases into liquid fuels,

through biotech solutions for transformation of carbon

monoxide to ethanol.[1]

TRL 4-6

Reduced direct emissions and

65% secondary reduction [2]

(CO2 emissions from

Steelanol-biofuels are 50-70%

lower than petroleum-based

fuels, and around 35%

compared to when steel plant

off-gases are converted into

electricity.[1].If fully deployed,

emission reductions of 65%

could be achieved through EU

bioethanol production of 2.5

Mn tons) [3]

Low additional energy demand

(Improved overall efficiency for

steel plant off-gases.

Meanwhile, the CO will not be

valorized in an electric power

plant [2]

1) Steelanol (2018). Official webpage. Available at:

http://www.steelanol.eu/en

2]Vlaamseklimattop (2015). Project “Steelanol” -

First commercial project for advanced bio-fuel

production from waste gas. Available at:

http://www.vlaamseklimaattop.be/sites/default/files/

atoms/files/ArcelorMittal%20-

%20project%20Steelanol.pdf

3) INEA (2017). Horizon 2020 – Energy and

Transport. Compendium of projects implemented

by INEA. Available at:

https://ec.europa.eu/inea/sites/inea/files/h2020-

compendium_2017_web.pdf  

Carbon2Chem CCUBased on utilisation of industrial waste gases, aiming to use

top gases for chemicals production (e.g. methanol) [1]TRL 7-8

Utilization of approx. 60% of

the Top Gasesn.a.

Carbon2Chem (2018). Official homepage. Available

at:

https://www.thyssenkrupp.com/en/carbon2chem/#4

20627

2) The Bio Journal (2018). 60 million euros for

Carbon2Chem project. Available at:

http://www.thebiojournal.com/60-million-euros-for-

carbon2chem-project/

FReSMe CCU

The FReSMe technology captures CO2 from steel production

for production of methanol fuel to be utilised in the ship

transportation sector. Project linked to the STEPWISE and

the MefCO2 technologies. [1]

TRL 3-5 n.a. n.a.

1) FReSMe (2018). Official webpage. Available at:

http://www.fresme.eu/about.php

2) CORDIS – FreSMe (2018). From residual steel

gasses to methanol. Available at:

https://cordis.europa.eu/project/rcn/205958_en.html

Stee

l

The project has received €9Mn funding from German

Federal Ministry of Education and Research (BMBF), within

its scheme “Technologies for Sustainability and Climate

Protection – Chemical Processes and Use of CO2.

H2 future has received funding under EU Horizon 2020's

project Fuel Cell and Hydrogen (FCH-02-7-2016). Expected

project cost is €17Mn.

SUSTEEL has received funding under Austrian FFG Project:

Production of the Future (15th Call). Expected project cost is

€2,6Mn.

The project is funded under H2020 Spire (H2020-EU.2.1.5.3.

- Sustainable, resource-efficient and low-carbon

technologies in energy-intensive process industries) [3]

The project has received €10,2Mn funding from the

European Union’s Horizon 2020 research and innovation

program under grant agreement No 656437. xliv Expected

project cost is €14Mn

The project has received over €60Mn from the German

Federal Ministry of Education and Research. The partners

involved intend to invest >€100Mn by 2025. They have

earmarked > €1Bn for commercial realisation [2]

This project has received funding from the European Union’s

Horizon 2020 research and innovation programme under

grant agreement No 727504 [2]

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STEPWISE CCU

STEPWISE captures blast furnace gases and processes

them through advanced water-gas shift technology. The

cases are cleaned through SEWGS (Sorption Enhanced

Water-Gas Shift [1]

TRL 3-4

85%

(85% reduction in carbon

intensity due to higher carbon

capture rate) [2]

60%

(60% lower SPECCA - Specific

Energy Consumption for CO2

Avoided) [2]

1) STEPWISE (2018). Official webpage:

http://www.stepwise.eu/project/ 

2) CORDIS – STEPWISE (2018). STEPWISE.

SEWGS Technology Platform for cost effective

CO2 reduction the in the Iron and Steel Industry

Available at:

https://cordis.europa.eu/project/rcn/193748_en.html

MefCO2 CCUBased on synthesis of methanol from captured CO2 using

surplus electricity. The technology will use H2 from water

hydrolysis as reactant. Project linked to FReSMe.

TRL 1-3 n.a. n.a.

CORDIS – MefCO2 (2018). MefCO2. Synthesis of

methanol from captured carbon dioxide using

surplus electricity. Available at:

https://cordis.europa.eu/project/rcn/193453_en.html

Hisarna - process

integration (with

CCS)

Energy

Efficiency/CCS

HIsarna is a new type of furnace in which iron ore is directly

injected, and liquefied in a high-temperature cyclone so that it

drips to the bottom of the reactor where powder coal is

injected. The two react into liquid iron.[1]

TRL 7

Min 20% emission mitigation;

35% (with high scrap use);

80% (with CCS) [2]

 80%

(At least 20% lower energy

demand than BF-BOF) [3]

1) HIsarna (2018). Official webpage. Available at:

https://www.tatasteeleur

2) Eurofer (2017). EU ETS REVISION: Unlocking

low carbon investments in the steel sector.

Presentation 18.01.2017 (Strasbourg). Available at:

https://www.google.be/url?sa=t&rct=j&q=&esrc=s&s

ource=web&cd=1&cad=rja&uact=8&ved=0ahUKEw

ii3b2ysevYAhWEZlAKHXMSABsQFggpMAA&url=h

ttp%3A%2F%2Fwww.eurofer.be%2FNews%26Eve

nts%2FPress%2520releases%2Fws.res%2F18011

7New%2520Unlocking%2520presentations%2520

All.pdf&usg=AOvVaw2CdiIuMMIv7jRM3q7VCS7Uo

pe.com/en/innovation/hisarna 

3) HIsarna Factsheet (2018). Factsheet. Available

at:

https://www.tatasteeleurope.com/static_files/Downl

oads/Corporate/About%20us/hisarna%20factsheet.

pdf  

4) Birat, Jean-Pierre. (2017). Low-carbon

alternative technologies in iron & steel. Presented

at IEA 20.11.2017 (Paris). Available at:

https://www.iea.org/media/workshops/2017/ieaglob

alironsteeltechnologyroadmap/ISTRM_Session3_Bi

rat_201117.pdf

SIDERWIN -

electricity based

steel metallurgy

Electrification

SIDERWIN (previously ULCOWIN) is based on CO2-free

steelmaking through electrolysis, transforming iron oxide (e.g.

hematite) into a steel plate (at the cathode) and oxygen

(anode). [1]

TRL 4-5

87%  

(Reduction by 87% of direct

CO2 emissions) [1]

 

31%

(Reduction by 31% of direct

energy use) [1]

1) Siderwin (2018). Official webpage. Available at:

https://www.siderwin-spire.eu/  

2) Siderwin Work Packages (2018). Work

packages. Available at: https://www.siderwin-

spire.eu/content/work-packages

3) CORDIS – SIDERWIN (2017). Development of

new methodologies for industrial CO2-free steel

production by electrowinning. Available at:

https://cordis.europa.eu/project/rcn/211930_en.html

IGARElectrification/CC

U

Based on process-integrated CO2-capture through top-gas

recycling in a blast furnace. Use of plasma torch and reactor

to heat and reform gases, enabling less coke/coal

consumption.

n.a.

n.a.

(Potential CO2 savings of 0,1 -

0,3 ton CO2/ton of crude steel)

n.a. n.a. n.a.

Hensmann et al (2018). Smart Carbon Usage,

Process Integration and Carbon Capture and

Usage. Presentation at EU Industry Day,

22.02.2018, Brussels. Available at:

https://europa.eu/sinapse/webservices/dsp_export_

attachement.cfm?CMTY_ID=0C46BEEC-C689-

9F80-

54C7DD45358D29FB&OBJECT_ID=3978AFA1-

B5F7-F82B-

80B5AA99F67F40D5&DOC_ID=3A6FBC05-DAFF-

1861-B14414BB2A8E8560&type=CMTY_CAL  

PEM

Materials

Efficiency/Energy

Efficiency

Enables melting of low-quality scrap with metallurgy/natural

gas (pre-melting in shaft vessel, subsequent superheating

process).

n.a.

n.a.

Potential CO2 savings of 1 ton

CO2 per ton melted scrap

n.a. n.a.

32%

(32% lower overall primary

energy consumption)

Hensmann et al (2018). Smart Carbon Usage,

Process Integration and Carbon Capture and

Usage. Presentation at EU Industry Day,

22.02.2018, Brussels. Available at:

https://europa.eu/sinapse/webservices/dsp_export_

attachement.cfm?CMTY_ID=0C46BEEC-C689-

9F80-

54C7DD45358D29FB&OBJECT_ID=3978AFA1-

B5F7-F82B-

80B5AA99F67F40D5&DOC_ID=3A6FBC05-DAFF-

1861-B14414BB2A8E8560&type=CMTY_CAL

Carbon Capture and

StorageCCS

Whilst carbon capture  is applied in fertilizer production, the

storage of carbon has not been used in the EU on an

industrial scale; Industrial scale CCU is performed in part of

the ammonia industry where some CO2 is used for melamine

or CaCO3 production (long term capture)

n.a. - - - - Fertilizers Europe (sector input)

Received €8,6 Mn from the EU’s Horizon 2020 research and

innovation programme under grant agreement No 637016

Expected cost is €11 Mn.

The project has received funding under Horizon2020 (SILC-

II). To date, €75 has been invested into the project, of which

60% has been funded by the partner companies and 40%

from the EU, the Dutch Economics Minstry and the

European Research Fund for Coal and Steel. Expected

project cost €300Mn.[3]

The project has received €6,8 Mn through SPIRE (H2020

2.1.5.3). [3]

Che

mic

als

& F

erti

lizer

sSt

eel

Received funding under EU Horizon 2020's project (LCE-15-

2014). Expected project cost is €13M [2]

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Further energy

efficiency measures

combined with

electrification.

(combination of

measures)

Energy Efficiency

+ Electrification

Combination of efficiency measures, plant retrofits, transition

to power-based heat and steam generation and recuperation

of waste heat.

TRL 7-9

Out of the 101 Mt/y savings in

the ambitious scenario by

Dechema study (ref. BAU), 20

to 30 Mt CO₂ of emission

savings can be achieved by

further efficiency measures

and plant retrofits, transition to

a power-based heat and steam

generation and recuperation of

waste heat. Energy efficiency

measures alone deliver 8.3

Mton reductions. Electricity

based steam and steam

recompression: 22.6 Mt/y.

(both figures in ambitious

scenario by Dechema study)

Note: Dechema study covering

ammonia, methanol, ethylene,

propylene, chlorine and the

aromatics benzene, toluene

and xylene representing 2/3 of

current GHG emissions in

chemical sector.The

quantitative analysis is based

on existing technologies, and

scenario development up to

2050 do not take into account

the development of next

generations or breakthrough

technologies. )

CEFIC (sector input)

OPEX per kW are expected

to almost half by 2050

Around 50-55%

(2,1 kWh/nm3 (H2) compared to

3,8-4,2 kWh/nm3 (H2) though

steam methane reforming)

DECHEMA p.47-48

Methane pyrolysis H2Methane or other lower hydrocarbons are decomposed in a

high temperature pyrolysis process generating hydrogen and

solid carbon.

TRL 4-5

Up to -100%

(If heating happens through

electricity, and provided full

decarbonisation of the power

sector)

Investment cost: EUR 3500 (t

H2/year)n.a.

High-temperature

solid-oxide

electrolysis

H2

Operating at a high temperature (around 700-1000°C)

reduces the electricity requirements for splitting water into its

elements down to 2.6 kWh per Nm3. Due to the high

temperature, a ceramic material capable of conducting

oxygen ions is required in the cell membrane.

TRL 6-7

Up to 100% (Provided

decarbonisation of the power

sector)

CAPEX currently at

€1000/kW.

input: natural gas 4.5 t/ t H2,

electricity: 9.5 MWh/t H2

Output:  carbon 3.3 t/ t H2

DECHEMA, p.53 and CEFIC (capex and energy)

Up to 100% (Provided

decarbonisation of the power

sector)

CAPEX currently at

€1000/kW, predicted to

decrease to €500/kW in 2030

DECHEMA

(2017). Technology study: Low carbon energy and

feedstock for the European chemical industry.

Commissioned by  

CEFIC. P. 36-38. Available at:

https://dechema.de/dechema_media/Technology_s

tudy_Low_carbon_energy_and_feedstock_for_the_

European_chemical_industry-p-20002750.pdf 

Alkaline electrolysis H2The state-of-the art industrial process for electrolytic

hydrogen production, using a 20-40% solution of KOH, with

Ni-coated electrodes as catalyst. 

TRL 7-9

Up to 100% (Provided

decarbonisation of the power

sector)

CAPEX currently at

€1100/kW, predicted to

decrease to €600/kW in

2030. 

OPEX per kW are expected

to almost half by 2050.

Around 108-113%

(4.3 kWh/nm3 (H2) compared to

3,8-4,2 kWh/nm3 (H2) though

steam methane reforming)

DECHEMA, p. 46-48

OPEX per kW are expected

to almost half by 2050

Around 105-116%

(4.4 kWh/nm3 (H2) compared to

3,8-4,2 kWh/nm3 (H2) though

steam methane reforming)

DECHEMA p. 47-48

Che

mic

als

& F

erti

lizer

s

Electricity based

steam productionElectrification

Enables decarbonisation by use of renewable energy, since

chemicals production's process energy demand is mainly in

the form of heat (steam). 60% of total fuel used in chemicals

production comes from fuel used to generate steam.

TRL 7

Up to -100%

(Provided decarbonisation of

the power sector)

n.a.

PEM-electrolysis H2

Runs on pure water and is designed for high pressures (up to

100 bars). The technology is dynamic and can be used in

dynamic systems (for example following the power-profile of

a wind turbine).

TRL 7-8

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Thermochemical

processesH2

Can be used for splitting of water (through high-temperature

heat) and of CO2. Direct water splitting requires more than

2000°C, and the process therefore requires catalytic

thermochemical cycles to reduce the temperature. The

thermochemical processes allow generation of syngas

(synthesis gas).

TRL 4 n.a. n.a. n.a. n.a. DECHEMA, p.53-54

Photocatalytical

processesH2

Splits water at the surface of a catalyst by using solar light

energy.TRL 2-3 n.a. n.a. n.a. n.a. DECHEMA, p.54

Hybrid Ammonia

production (H2 and

CH4)

H2In a hybrid plant for ammonia production, natural gas is used

as second feedstock and in addition to the previously

described hydrogen-based ammonia production.

n.a.

Higher CO2-emissions than

low-carbon ammonia, due to

use of fossil fuels.

Lower CAPEX than

electrolysis-based low-carbon

ammonia production, since no

Air Separation Unit is needed.

n.a. n.a. DECHEMA, p.59-60

Low-carbon

methanol

production (CO2 +

H2)

CCU/H2

Low-carbon methanol can be produced using hydrogen (e.g.

produced by water electrolysis with low-carbon electricity), in

combination with hydrogenation of CO2 as carbon source.

Hydrogenation of CO2 is used also in conventional methanol

production by adding small amounts of CO2 to adjust the

CO/H2 ratio of the syngas. Synthesis of methanol from CO

and CO2 are tied through the water gas shift reaction.

TRL 7

-145%

(Compared to natural gas

based methanol production;

negative number due to

utilisation of CO2)

CAPEX and OPEX similar to

production from natural gas.

CAPEX and OPEX similar to

production from natural gas.

105 to 111%;

or 5-11% higher if feedstock

(GJ) is included in natural gas

based methanol production

(37.5 GJ/t

DECHEMA, p.63-64

Olefins out of H2

and CO2 in single

system

CCU/H2

Olefins can be created from H2 and CO2 in a single system,

for example in a single-stage electro-catalytic process, which

omits the need for intermediate products (e.g. methane and

methanol as feedstock for olefin synthesis).

TRL 3-4 n.a. n.a. n.a. n.a. DECHEMA, p.68

Benzene, toluene

and xylenes (BTX)

via H2 based

methanol

CCU/H2BTX can be produced from hydrogen based methanol, which

requires a lower temperature and requires a higher catalyst

acidity.

TRL 7

-416%  

(Compared to Naphtha based

process) 

n.a. n.a.

1000%

(176 GJ/t compared to naphtha

based process 16.9 GJ/t)

DECHEMA, p.70-72

Poly(propylene)carb

onate and

polycarbonate

etherols using CO2

CCU

Poly(propylene)carbonate is a polymer that can be produced

using CO2 as building block. It is mainly used for packaging

foils/sheets. Polycarbonate etherols can also be produced

from CO2, and is mainly used in polyurethane foams.

TRL 7-9 n.a. n.a. n.a. n.a. DECHEMA, p.83

Formic acid (using

electrochemical

CO2 reduction)

CCUFormic acid can be produced through electrochemical CO2

reduction, and is mainly used for example as a preservative,

adhesive, precursor or as fuel in fuel cells.

TRL 7 n.a. n.a. n.a. n.a. DECHEMA, p.83

Mineral carbonation CCUMineral carbonation can be used for treatment of industrial

waste, metallurgy slag, production of cementitious

construction materials etc.

TRL 7-9 n.a. n.a. n.a. n.a. DECHEMA, p.83

Dimethylether DME

(direct synthesis

from CO2)

CCUDimethylether (DME) can be produced through direct

synthesis from CO2, and used as a fuel additive or a LPG

substitute.

TRL 1-3 -30% n.a. n.a. n.a. DECHEMA, p.83

Sodium acrylate

from ethylene and

CO2

CCUSodium acrylate from ethylene and CO2 is currently

investigated in lab scale. TRL 1-3 n.a. n.a. n.a. n.a. DECHEMA, p.83

Electrocatalytic

processes to

convert CO2 to

ethylene

CCUConversion of CO2 to ethylene through an electro-catalytic

process is currently investigated in lab scale. TRL 1-3 n.a. n.a. n.a. n.a. DECHEMA, p.83

200-500 €/ton of product.

OPEX around 1.5 times

higher

117%

(Compared to gas-based route;

14.6 GJ/ton of methanol

compared to 12.5 GJ/t for CH4

based methanol production

excl. feedstock)

DECHEMA, p.85-96Biomethanol Biomass

Biomethanol is produced via gasification of bio-based

feedstock, in the same way as coal-based methanol

production. A large variety of biomass feedstock can be used

(e.g. wood compared to sugar and starched crops), which

generate different yields, costs etc.

TRL 6-7

-24% without sequestered

carbon and -187% including

carbon sequestered in

biomass

(compared to gas-based route;

ref. 0.84 t CO2/tons of

methanol via CH4)

CAPEX (per unit of capacity)

around 3.4 times higher for

the biomass route. Notably,

biomethanol plants are

around 1.8 times more

expensive (based on the

same energy output)

compared to bioethanol

facilities

Low-carbon

ethylene and

propylene via MTO

(Methanol to

Olefins) and

methanol is made

using H2 and CO2

CCU/H2

Low-carbon ethylene and propylene can be produced via

MTO (Methanol to Olefins), if methanol is made using H2 and

CO2 as previously described. The MTO reaction is strongly

exothermic and the process follows a two-step dehydration of

methanol to dimethyl ether and water, to control the heat of

reaction and the adiabatic temperature increase, followed by

the conversion to olefins.

TRL 7 (Although MTO

technology is well

known, the TRL is

limited by the TRL of

methanol production

from CO2 and low-

carbon H2)

Approx -249% (in the MTO

process -1.13 t CO2/t olefin ,

compared to the naphtha route

0.76 tCO2/t olefin)

Major economic constraints:

new investments needed in

both hydrogen-based

methanol plants and MTO

plants.

n.a.

500%

(In comparison to the naphtha

route 16.9 GJ/t)

DECHEMA, p.68-69

Low Carbon

Ammonia (H2

based)

H2

Low-carbon ammonia synthesis is therefore limited to an

alternative, low-carbon hydrogen production, where hydrogen

is produced through electrolysis. No CO2 is formed as co-

product in this synthesis route.

TRL 7

Up to -100%

(Provided full decarbonisation

of the power sector; compared

to 1.83 tCO2/tNH3 for CH4

based ammonia production)

The low-carbon route has 2

times higher CAPEX than

conventional production

[p.127]

3 times higher OPEX than

conventional production

[p.127]

130% (including feedstock) DECHEMA p.56-57

Che

mic

als

& F

erti

lizer

s

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Bioethylene Biomass

Bioethylene production is based on bioethanol as feedstock

(as described above), through dehydration of the ethanol.

One ton of bioethylene requires 1.74 t of (hydrated) ethanol,

and wood-based bioethylene production requires 10.5 t

feedstock/ton bioethlyene.

TRL 8-9

0% without sequestered

carbon, -270% including

sequestered biomass

506%

(85.5 GJ/t of ethylene compared

to 16.9 GJ/t via naphtha route)

DECHEMA, p.90-92

Biopropylene Biomass

Bio-propylene production is based on bio-ethylene production

through catalysis. A couple of alternative routes exist, but at

lower TRL, among them fermentative production of propanol

or isopropanol.

TRL 6-7

+62% without sequestered

carbon and -120% including

sequestered carbon

565%

(95.5 GJ/t of propylene

compared to 16.9 GJ/t via

naphtha route)

DECHEMA, p.92-93

BTX from biomass Biomass

BTX can be produced from biomass through several routes,

but the most developed route is through gasification of

biomass, thereafter methanol synthesis and thereafter

methanol to aromatics (MTA) (with these individual process

steps as previously described). Alternative routes are

synthesis of p-xylene (pX), selective degradation of lignin and

fast pyrolysis of lignocellulosic biomass.

TRL 6-7

+210% without sequestered

carbon and

-180% including sequestered

carbon

426%

(72 GJ/t of BTX compared to

16.9 GJ/t via naphtha route)

DECHEMA, p.93-96

-90% of energy use (1.68 GJ/t)

for ethanol to ethylene,

compared to Naphtha to

ethylene (16.9 Gt/t)

DECHEMA, p.101-103

DECHEMA, p.87-96

2250-2800 €/ton of product

2200-2500 €/ton of product

>3000 €/ton of product

Ethanol to ethylene

(with ethanol

originating from

biomass or

Biomass/CCUEthanol can be turned into ethylene through a relative

straightforward and energy efficient dehydration process.n.a.

Mitigation potential and total

energy use depend on source

and process to create ethanol

from syngas

n.a.

Bioethanol Biomass

Bioethanol is produced via biomass pre-treatment (extraction

of sugar e,g, via heat extraction and vaporization),

refinement, and then fermentation to an ethanol solution with

about 12% ethanol content, which is being distilled to 96%

ethanol. Further dehydration is needed for use as biofuel.

TRL 6-7

n.a.

(Strongly dependent on type of

biomass, process and scope;

Dechema report estimates

0,305 ton avoided CO2/ton of

product)

975 €/ton of product. Production costs mainly depend (55-

80%) on biomass feedstock prices

n.a.

(47.7 GJ/ton of ethanol)

Che

mic

als

& F

erti

lizer

s

Page 20: Industrial Value Chain A Bridge Towards a Carbon …(cement stone) product can be used as filler in concrete with binding capacities, filler in cement with binding capacities, added

Sector Mitigation Costs InvestmentsKey Technologies

(included in roadmap and irrespective of scenarios)

Assumptions

Name: Scenario 1 Economic -13% BF-TGR, ULCORED/HIsarna Increased scrap availability

Published: Scenario 2 Maximum theoreticalAbatement w/o CCS -38% CCS Greater share of EAF steelmaking

Author: Scenario 3 Maximum theoretical Abatement with CCS -57% Electrification of heating Continuous decarbonisation of power sector

Commissioned By: Hydrogen-based reduction Continuous market growth

Source:Scope: EU 2013-2050

Name: Corex/Finex ironmaking EU steel demand will still be 8% lower in 2030 compared to 2007

Published: MIDREXEU steel exports will decline in future, fromtraditionally being a net exporter to becoming self-sufficient in steel by 2030

Author: EnergIron/HYL

Scrap requirements will increase. Availability of home and prompt scrap is expected to decrease. The recovery of obsolete scrap is expected to fall and remain relatively low. Scrap recovery rates are also expected to rise from their current 50% to 58% 

Commissioned By: Direct Sheet Plant (DSP)

Source: CCS

Top Gas Recycling Blast Furnance (Under ULCOS programme) AS1 scenario: increase of fuel and resource prices

HIsarna (Under ULCOS programme) AS2 scenario: variations in CO2 emission price 

ULCORED (Under ULCOS programme)

ULCOWIN (Under ULCOS programme)

Name: Improving energy efficiency by deployingtechnologies and retrofitting facilitites

12-23% global increase in cement production compared to 2014

Published: Switching to alternative fuels e.g. use of biomassand waste materials in cement kilns

Non-technical barriers to deployment technologies overcome e.g social acceptance, ineffective regulatory frameworks and information deficits.

Author: Reducing clinker to cement ratio

RoadmapsPathways

Cumulative additional investments of $107 Bn- $127Bn by 2050 compared to a situation where the current energy and carbon emissions footprint of cement making remain unchanged.

Alternative scenario 1(AS1). Two cases: 2x-Fuel price and 5x-Fuel price (of BS scenario)

-16% (for 2x-Fuel) -21% (for 5x-Fuel)

Prospective Scenarios on Energy Efficiency and CO2 Emissions in the EU Iron & Steel Industry

Technology Roadmap: low carbon transition in the cement industry

2012

Cem

ent

European Commission

Link

Stee

l

BS scenario: demand for steel and, prices of fuels and resources evolve according to the projection of the European Commission. 

2018

IEA

Electrolysis

A Steel Roadmap for a Low Carbon Europe 2050

Scenarios

Scenario 2

Baseline scenario (BS) -14%

Emissions Reductions with BTT -80%

Scope: EU 2010-2030

Scenario 1

There will be no more than six retrofits for the integrated and secondary steel routeper year.

JRC EC

2014

EUROFER

EUROFER

Roadmap-Pathways

Scenario 4

Scenario 3

Alternative Scenario (AS2). Two cases for CO2 price:100€-CO2 and 200€-CO2

-15% (100€-CO2) -19% (200€-CO2)

Scenario 1 Reference Technology Scenario (RTS) 4% (global increase)

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Commissioned By:

Using innovative tech that contribute to decarb ofelectricity generation by adopting heat recoverytech and support of renewable-based powergeneration

Source: CCSScope: Global NA-2050 Alternative binding materials

Name: Scenario 1 Resource efficiency Same production volume

Published: Scenario 2 Energy efficiency Fully decarbonised power sector by 2050

Author: Scenario 3 Carbon sequestration and reuse

Use of alternative fuels composed of 60% alt fuels (40% of which would be biomass), 30% coal and 10% petcoke. Assumed no improvements in energy consumption for fossil fuels

Commissioned By: Scenario 4 Product efficiency Reduction in post-cement plant transport emissions with share of road transportation 50%, rail 23% and

Source: Average plant production capacity to double

Scope: EU 1990-205050% increase in the efficiency of all modes of transport

Name: Bio-based feedstock Competitiveness

Published: Valorisation of waste and recycling of plastics Energy priceAuthor: CCU/CCS Impact on productionCommissioned By: Greater process energy efficiency CO2 priceSource: Heat recovery and reuse Feedstock prices

Renewable energy and CHP Value chain integrationEnd of pipe emission abatementMeasures that reduce emissions in nitric acid Mitigation options for ammonia, cracker products

Name: Abatement category 1: Raw materials

Mature tech implementable in near to medium term e.g. PVC recyling, retrofit polyurethane insulation in homes and buildings, more efficient chlorine electrolysis technologies, increased re-refinement rate of polyalphaolefins, greener foam blowing agents for polyurethane. 

All of today’s emissions (direct and indirect) are covered by the ETS, the average chemical plant emits 30% more emissions relative to its respective benchmark, and the cross-sectoral reduction factor applies. Net costs after 2020 depend on further decisions on 2030 EU climate package

Published:Abatement category 2: Chemical Production 

Circularity e.g. production of new carbon fiber, recycling of PVC

Recycling rate to increase to 85-95%  in production waste, and up to 5% in construction waste

Author: Abatement category 3: End-product Usage

Products and materials substitution e.g. replacing polycarbonate with bio-based plastics, switching from polyalphaolefins to bio- based oils, and replacing PAN with lignin or polyethylene in carbon fiber production

‘Impact on competitiveness’ of every lever is assessed, assuming it would be implemented in the near term

Commissioned By:

Renewable feedstock, e.g: renewable carbon in polyol production for polyurethane, using bio-ethylene in PVC production, and replacing phosgene with CO2 based feedstock in polycarbonate production

Source: Shift to green energyScope: EU NA-2030 CCS

DownstreamScenario 5

CCS increases production costs by 25-100%. CAPEX  €330-360 Mn to deploy full oxyfuel technology at new 1 Mn tonne/year plant, €100Mn for retrofitting oxyfuel technology, €100-300 Mn to retrofit existing plant with post-combustion technology. OPEX of plant w/ post-combustion CC = 2x conventional cement plant, oxyfuel use = 25% higher OPEX. Additional costs: compression, transport, injection and storage.

-32% compared with 1990 levels, using mostly conventional means.

-80% with application of emerging technologies, suchas CCS.

$176Bn - $244Bn additional investments to implement 2DS compared to RTS

-24%

CCS/CCU: Post-combustion CC technologies (e.g. chemical absorption, membrane technologies,  carbonate looping), oxyfuel combustion technology. 

Limited potential of carbon usuage in cement - carbon capture valorisation more applicable.

Scenario 2 2 degree Celsius Scenario (2DS)

Abatement category 4: End of Life 

Scenario 2 Isolated Europe Scenario -80%

Level Playing Field ScenarioScenario 4

1990-2050EUScenario 3 Differentiated Global

Action Scenario -80%

Continued Fragmentation Scenario

-40%

Link

European Chemistry for growth, unlocking a competitive, low carbon and energy efficient future

ECOFYS & CEFICCEFICLink

Europe’s low-carbon transition: understanding the challenges and opportunities for the chemical sector

2014

ECF & McKinsey

ECF

Link

Cembureau

Scenario 1

Biological carbon capture

Cembureau

Scope:

Chem

ical

sCe

men

t IEA

Link

The role of cement in the 2050 low carbon economy

2013

2013

Lifecycle analysis of 5 chemical products showed: -50 to -75% of scope 1 and 2 emissions, relative to estimated frozen technology baselines. Additional Scope 3 reductions of more than 90 MtCO2e

(scope 1 = direct, scope 2 = indirect, scope 3 = other industry emissions)

Scenarios

-50%

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Name:

For energy: 16% of saving attributed to savings in feedstock (e.g. such as production of hydrogen from electrolysis or production of chemicals from biomas). 84% savings from electricity or fuels (used for thermal needs or steam processes).

European industry remains globally competitive and demand is met with production

Published:

For soda ash the most important BAT is integrated design and operation, while for ethylene oxide/monoethylene glycol the savings are firstly due to adoption of the OMEGA technology and further installing CHP, but mainly thanks to CCS.

An increase by 45.6 % of the demand in the Baseline Scenario

Author: CHP

In BS: prices for CO2.eq allowances, fuels and feedstocks follow the assumptions of the 2013 EU Energy and GHG emissions reference scenario (EC, 2013)

Commissioned By: CCS

Source:

Scope: EU 2013-2050

Name: Scenario 1 Business as Usual

+119 MtCO2 (an increase proportional to production volume. Savings from efficiency measures not included)

€2,1 Bn/annum 

Energy efficiency Increased demand for low carbon power

Published: Scenario 2 Intermediate

-117 MtCO2 (incl. savings made from production of synthetic fuels)

€17,0 Bn + €14,1 Bn (for efficiency measures) per annum Hydrogen & CO2 based production routes Increased demand for CO2 as feedstock

Author: Scenario 3 Ambitious

-216 MtCO2 (incl. savings made from production of synthetic fuels)

€19,2 Bn + €14,1 Bn (for efficiency measures) per annum Biomass & biomass waste streams to chemicals Increased demand for biomass as feedstock

Commissioned By: Electricity-based processes Extensive additional investments

Source: Industrial symbiosis & circular economy 1 % growth per annum for the EU chemical industry

Scope: EU 2015-2050 CCS In BAU scenario: the power sector does not showfurther progress in decarbonizationEName: Scenario 1 Substituting raw

materials12 Mt looped chemicals CAPEX €20-40 Bn  Biomass

Published: Scenario 2 Increased re-use ofend-user products

17 Mt looped chemicals

CAPEX n.a. New products and solutions that can essentially bere-used “as is”

Author: Scenario 3 Mechanical recycling 19 Mt looped chemicals CAPEX €10-20 Bn  Mechanically recycled molecules

Commissioned By: Scenario 4 Chemical recycling 8 Mt looped chemicals CAPEX €30-80 Bn  Reverse logistics capabilities

Source: Processing partnerships

Cracking and gasification processesMolecular energy recovery, capture andreconstruction of new chemical feedstocks

Fuel price variations (AS1). AS1a medium fuels prices (2x baseline); AS1b high fuel prices (5x baseline); AS1c very high fuel prices (10x baseline). NB: baseline price corresponds to 'low prices' of the baseline scenario

JRC EC

-36%Baseline scenario

No remarkable difference compared to baseline scernario

Scenario 1

Scenario 2

Energy efficiency and GHG emissions: Prospective scenarios for the Chemical and Petrochemical Industry

€26,7 Bn+ €14,1 Bn (for efficiency measures) per annum

Low carbon energy and feedstock for the European chemical industry

Advanced process control- improvements compression and separation section and the use of adsorption heat pumps, improved furnace design and the use of membranes in the separation section

Similar to baseline; max saving by most favourable scenario delivers additional 0.8% CO2 savings to BS i.e. -36.8%

CO2 price variations (AS2). 3 cases: Medium price (AS2a, 2x baseline); High price (AS2b, 5x baseline); Very high price (AS2c, 10x baseline).

Scenario 3

Link

Chem

ical

s

Scope:

Taking the EU chemicals industry into the circular economy

2017

Link

Energy recovery and carbon utilization

10 Mt looped chemicals CAPEX €100-140 Bn

EU

ACCENTURE

2017

CEFIC

-498 MtCO2 (incl. savings made from production of synthetic fuels)

MaximumScenario 4

CEFIC

DECHEMA

2017

Scenario 5NA-2030

Lesser production of virgin chemicals would save around 250 TWh of energy

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Name: CircularityEnergy efficiency improves at 1.0%/year after 2005

Published: Alternative feedstock Continued added value growth of 1% per yeatAuthor: Energy efficiency

Commissioned By: Renewable energy

Source: CCSScope: Netherlands 1990-2050 Sustainable products

Name: Kiln switch: horizontal kilns to vertical kilns (PFRK's)

Published: Kiln switch: LRK to PRK

Author: Kiln switch: other vertical kilns to PFRK

Commissioned By:

Improved use of waste heat-to be used in other sectors or for supply to buildings/residential areas. Use of Organic rankin cycle (ORC) to convert into electricity

Source: Energy recovery in hydration (generates heat with potential uses in other industries) 

Other measures: Efficient insulation lining to minimize shell heat losses, optimal combustion process, improved process and input control, optimal change-over management, optimal maintenance.

CCS, including: MEA, oxy-firing and capture Using limestone

CCU utilisation to: produce fuels/hydrocarbons, convert minerals into inert carbonates, use as feedstock, enhance recovery of fossils (oil, gas)

Name: Energy Efficiency

Published: Low Carbon Energy Sources

Author:

Commissioned By:Source:Scope: EU NA-

2030/2050

Scenario 1Constant refining capacity (EU,  2030 level), all options are exercised, different rates of deployment of technology, energy prices & degree of  electricity grid decarbonisation

Scenario 1

Concawe

Concawe

2050 Scenario CAPEX €40+ Bn

Chem

ical

sRoadmap for the Dutch Chemical Industry towards 2050

2018ECOFYS & Berenschot

VNCI

LinkScenario 2

Direct actions and high-value applications

Scenario 2

80-95%

Scenario 1 2030 compliance at least cost 80-95%

2030 Scenario -20 to -30% (à2030)

Energy efficiency measures

Lower-carbon energy sources

Abatement potential not established (but potential at most 31%). Decrease in carbon intensity of power generation of 42% (2030) and 71% (2050). Even without action from the lime industry the CO2 emissions associated with its electricity use will drastically decrease.

Biggest abatement potential of all

CO2 Capture (combination of CCS and steam reforming plants)

Investment costs: €16 Bn in the chemical industry, €25 outside the chemical industry

(up to 2050)

Investment costs: €27 Bn in the chemical industry, €37 outside the chemical industry

(up to 2050)

-70% (à 2050 with CCS, -50% w/o CCS)

EU 2010-2030/2050

CO2 abatement costs ≥ €38/tonne

CO2 abatement costs of:

Switching all solid fossil fuels to natural gas €91/tonne

Switching all solid fossil fuels to biomass €43/tonne

No investment needed for switch to natural gas. 

10.9 €/GJ investment costs for switch to biomass

Scenario 3End of pipe solutions (CCS, CCU and carbonation)

€76/tonne CO2 avoided

Rotary kilns to Shaft kilns -€100/tpy

LRK to PRK -€72.5/tpy

All shaft kilns to PFRK -€100/tpy

€94/tonne of avoided CO2. Cost for CC would more than double production costs to €60/tonne lime. Use of waste heat for solvent regeneration to reduce costs

A Competitive and Efficient Lime Industry, Cornerstone for a Sustainable Europe

Lim

e

Around halve of thetheoretical potential for energy efficiency improvements could be captured. Energy efficiency improvements for lime products of 16% are projected for 2050

Link

2018

2014

ECOFYS

EULA

Scope:

Refin

ing

Low Carbon Pathways CO2 efficiency in the EU Refining System. 2030/2050

Scenario 2

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Name:

In paper production: machine’s drying section, layered sheet-forming, advanced fibrous fillers and selective fractionation processes to reduce heat demand in paper production.

The expected decarbonisation of electricity, carbon neutrality of biomass, availability of CCS and the realisation of energy efficiency targets 

Published:

In pulp production the focus is on improving efficiency of existing processes (notably in refining and grinding for mechanical pulp production and the use of wood chops to reduce electricity consumption)

Accepts  Commission’s assumption that a projected rise in CO2 price from 17 euro/t in 2010 to 190 euro/t in 2050 will have consequences that drive coal replacement, boosting demand for wood for energy by 35% from 2010-2050

Author:

Other ET in energy conversion, biomass and waste/residue gasification, black liquor gasification, torrefaction, carbonisation and pyrolysis are also considered. 

Expected rise in imports of biomass or wood, rejecting that Commission's prediction that imports will not increase to meet demand for large-scale electricity production 

Commissioned By:

For wood: laser cutting technologies, material savings, wood drying concepts and development of glues, paints, coatings and further treatment for increasing durability of wood (p.22).

Growth of  industry to be in line with EU GDP of 1.5% a year for 40 years, with 50% more added-value by 2050.

Source: Increased recyling and better sorting

CCS

Industrial symbiosis- integrated biorefinery complexes

CHP

Name: Energy efficiency improvements Value added compared to 2010 to increase by 50%

Published: Demand-side flexibility Shift to the circular bioeconomyAuthor: Fuel switch

Commissioned By: Emerging and breakthrough technologies

Source: Carbon reduction from purchased electricityScope: EU 28 1990-2050 Transport improvements

Name:

Energy efficiency (such as kilns, dryers,thermostats and seals, application of automatedcontrols, and heat saving through improvements inthermal insulation)

Energy costs 2.5x current rate

Published:Alternative fuel sources (such as theelectrification of kilns and using low carbonelectricity)

Cost of biogas 2-3x that of natural gas

Author: Smart design of facilities Rising cost of raw materials from Asia

Commissioned By: Integrated process efficiencies Constant level of production with a similar productmix

Source: Cogeneration through CHPBarriers regarding alternative fuels are overcome and regulators treat syngas and biogas as producing net-zero emissions

Scope: EU 1990-2050 CCS

Scenario 1

Scenario 2

-80%

-50 to -60%

Implementation of BAT, emerging technology (ET) and current investment patterns 

-25% (compared to 2010)

Scenario 3Breakthough technology developed and available by 2030

CAPEX €90 bn + €40 Bn for writing off plants before the end of their lifetime. High cost of power compared to natural gas

EU 1990-2050

Costs of capitalstock turnover over 40 years will be €260 Bn or €6 Bn / yr compared to recent investment levelsof €5.5 Bn/yr 

Investments in emerging technologies (i.e., on top of a change in BAT due to capital stock turnover)will be up to 10% extra for the globalpulp and paper sector

40% more investments than current levels. Extra €24 Bn by 2050 for decarb measures and €20 Bn forproduction of new bio-based products. (Calculated for CAPEX only)

Assumption that BTT enter the market at no more than 10% greater cost than existing or ET

Half of all kilns converted to electric and remainder to syngas or biogas co-fired with natural gas)

Cerameunie

Link

-65%

-78%

Scenario 1 Scenario -80%CEPI

CEPI

Scenario 1 Current and identifiedfuture technologies

Fore

st F

ibre

(Pu

lp, P

aper

, Woo

d)

Link

Investing in Europe for Industry Transformation: 2050 Roadmap to a low-carbon bio-economy

2017

Scenario 2

Link

Scope:

CEPI

Unfold the Future - 2050 Roadmap to a low-carbon bio-economy

2011

CEPI

All equipment replaced with BAT

2012

Cerameunie

Cera

mic

s

The Ceramic Industry Roadmap: Paving the way to 2050

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Name: Metal demand per unit of installed capacity will remain constant 

Published: Mixes of sub-technologies in future energy scenarios

Author: Technology lifetimes same as today's average

Commissioned By: Metal recyling rates ignored in analysis

Source:

Scope: Global 2013-2050

Name:

Published:Author:Commissioned By:Source:

Scope: EU NA-2050

Name:The EU electrical power sector will achieve the CO2 intensity reductions projected by the European Comission

Published: The aluminium sector will be able to purchase clean electricity at internationally competitive prices

Author:

Commissioned By:

Source:

Scope: EU 1990-2050

Scenario 1

[Use of the IEA's Energy Technology Perspectives ETP scenarios] 2DS

Scenario 2 4DS

Study examining demand in metals for use in low-carbon technologies e.g. wind turbines, solar PV, energy storage. The analysis indicates a rapid rise in demand for relevant technologies and corollary metals between reaching a 4DS and 2DS climate objective. Relevant metals demand roughly doubles for wind and solar technologies. Energy battery storage technologies require more than a 1000% rise for metals.

Since nickel is present in those 3 scenarios, whichever scenario is chosen, future demand for nickel is set to increase

Climate Change. Nickel is part of the solution

2017

World Bank

An aluminium 2050 roadmap to a low-carbon Europe

Link

Nickel and nickel alloys - as corrossion resistant materials- are essential materials for technologies that will satisfy growing energy demand while achieving CO2 reduction targets: Carbon Capture and Storage facilities, low-carbon energy such as biomass, nueclear, wind, solar, hydro-electric power, or a combination of all these technologies.

Nickel Institute

n.a.

Primary plants could begin to replace old technology with new non-emitting technology by 2030

2017

European Aluminium Assotiation

Scenario 2 Low carbon energy sources

World Bank

Link

Scenario 3 6DS

-60% by 2050 with emissions continuing to decline after 2050 until carbon neutrality is reached

LinkNon-

ferr

ous

met

als

The Growing Role of Minerals and Metals for a Low Carbon Future

European Aluminium Assotiation

 -60% isolated scenario -80 to -90% (3 scenarios

n

Scenario 1

Nickel Institute

Carbon Capture and Storage

Scenario 3 IEA Blue Map strategies

2012

Primary energy demand and CO2 emissions grow by about 60% 

-80 to -90% (3 scenarios combination)

The industry will have favourable conditions to invest in Europe

 -80 to -90% (3 scenarios combination)

Scenario 1

EC's scenario on reductions of emmissions from European power generation (92%) combined with aluminium industry to reduce its indirect emissions (70%)

79%

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Name:Motor efficiency Improved energy efficiency

Published: Transformer efficiency Use of renewable energy sources 

Author: Cable efficiency Demand-side management, storage and hybridsystems 

Commissioned By: Solar thermal technologies Electrification

Source: Electrification of thermal processes

Building energy management

Wind powered industrial processes

No specific technology related to transportation

Name:

Published:

Author:

Commissioned By:

Source:

Scope:European Pulp & Paper transport

1990-2050

Name: B2DS Scenario:

Published: Energy efficiency & BAT deployment (42%)

Author: Innovative processes & CCS (37%)

Commissioned By: Lower carbon fuels & feedstocks (13%)

Source:Scope: Global 2014-2060

Scenario 1

Scenario 2

Four available pathways: vehicle fuel efficiency improvement, fuel shift, logistics eficiency, digital solutions

-60%

4 pathways above + R&D, integration and inovation deployment

-80%

European Copper Institute

Link

Scope: EU 1990 - 2050

Non-

ferr

ous

met

als

Scenario 1

Relevant funding needs to be allocated to innovation for development of truck fuel efficiency, adaptation of alternative fuels and power sources in the transport sector, plus infrastructural and digital solutions to enhance logistical efficiency.

Copper's Contribution to a Low-Carbon Future. A Plan to Decarbonise Europe by 25%

CEPI

Decarbonising transport and logistics chains in Europe? Discussion paper

Link

2014

European Copper Institute

Scenario 2

Scenario 3

Reference Technology +0/6%/yr to (à2055 - peak)

2DS (2 degrees)

Copper-based technologies triggering downstream CO2 reductions.

Scenario 1

-25% relative to 2011.Annual emission savings- Motor efficiency:100 mt CO2; Transformer efficiency: 4 mt CO2; Cable efficiency:14 mt CO2; Solar thermal technologies: 300 mt CO2; Electrification of thermal processes: 290 mt CO2; Building energy management: 380 mt CO2; Wind powered industrial processes: 40 mt CO2

In cases where 100% electrification is possible, the need to invest in a costly parallel natural gas infrastructure would be eliminated

$6.8-8.0 Tn Investment

-80% (à2060)

-44% (à2050)

Energy Technology Perspectives

2017

IEA

n.a.

Material efficiency strategies (8%)

-60% (à2060)

-69% (à2050) $7.0-8.7 Tn Investment

Mul

tiple

Indu

stria

l Sec

tors

2018

CEPI

B2DS (below 2 degrees)

$6.3-7.3 Tn Investment

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Name:Energy effciency: increased penetration of today's effcient technologiesRenewables in heat/steam generation

Published:A learning curve in photovoltaics ("third generation") and electrochemical (and possibly alternative) storage technologies

Author:More efficient production and better solutions for transportation and storage of hydrogen, as well as more efficient power-to-X production processes

Commissioned By: New technologies in the bonding and storage of dissimilar carbons

Source: CCS (Steel, Ammonia, Cement, Rail, Waste Incineration)

Scope: Germany 1990-2050 CCU (for power-to-liquid/gas)

Name: Carbon capture Electricity grid decarbonisation

Published: Electricity grid decarbonisation Low stable growth

Author: Biomass

Commissioned By: Energy efficiency and heat recovery

Source: Electrification of heat

Scope: UK 2012-2050 Clustering

Name: Energy efficiency Conditionalities for the steeper route:

Published: Electrification of heat demand Shift from fossil-based electricity generation to renewables

Author: Change of feedstock Electrification of industry

Commissioned By: Routes to reuse and recycle materials Future electricity price

Source: Decide on steel production route(s)

Scope: Netherlands 2014-2050 CCS/U

Scenario 2 Cheaper route -60% (by 2040)€21-23 Bn (€6 Bn capital costs, €17 Bn for higher operating costs)

Scenario 3 Steeper route -80% (by 2040)-95% (by 2050)

€55 Bn (€25 Bn CAPEX) for 80% and €71 Bn (€25 Bn CAPEX, €46 Bn OPEX) for 95%

Energy transition: mission (im)possible for industry? A Dutch example for decarbonization

2017

McKinsey & Company

VEMW (Vereniging voor Energie, Milieu en Water)

Link

Scenario 1 Reference scenario

-40% (by 2030, with no significant reduction possible after)

n.a.

UK Gov.

Link

Continued deployment of energy efficiency technologies

-32% €6 BnScenario 1

Scenario 2 Maximum technology  -73% €16 Bn

95% climate path

For reference scenario: approximately 50% GDP growth by 2050

-61%

Scenario 2

Reference

Scenario 3

Scenario 1

Additional investments €230 Bn (for industry)

-95%

Mul

tiple

Indu

stria

l Sec

tors

Industrial Decarbonisation & Energy Efficiency Roadmaps to 2050

2015

Parsons Brinckerhoff & DNV GL

Klimapfade für Deutschland

€ + 9.7 Bn in 2050 (includes energy costs, energy savings, capital costs)

-80%

2018

BCG and Prognos

BDI

Link

Additional investments €120 Bn (for industry)

€ -4.2 Bn in 2050 (includes energy costs, energy savings and capital costs)

80% climate path

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Sector Technologies

Name: Strategic Research Agenda 1

Aim & approach:  the paper offers a global vision on the innovation and R&D initiatives which will lead to the

 achievement  of  the  objectives  identified  in  the  frame  of  a  sustainable  leadership  of  the  EU steel

 sector. 

Life cycle thinking, life cycle assessment

Published: 2017 2

The research and innovation approach: For low carbon steelmaking: initatives such as The Big Scale initiative,

can contirubte to reduce GHGs on two pathways: (1) Carbon direct avoidance (CDA), which substitutes carbon

as the reducing element with hydrogen or via the use of electricity, (2) Low carbon without CO2emissions

 LCWCE), which further optimises carbon-based metallurgy and applies CCS/CCU methods to mitigate GHGs 

Cyber-Physical Systems, Internet of Things (IoT) and Big-Data Technologie

Author:European Steel Technology

Platform (ESTEP)3

Introduction of Life Cycle Thinking (LCT) and the SOVAMAT initiative, which puts forward the concept of "social

value". Circular economy practices incl. industrial symbiosis

Commissioned by: n.a. 4Digital technologies for environmental impact assessment e.g. Cyber-Physical Systems, Internet of Things (IoT)

and Big-Data  TechnologiesEco-design and eco-labelling directives

Source: Link 5

Circular economy: Continued recycling is essential to keeping scrap in a constant loop. In such a way, steel can

be classified as a Permanent Material that once produced can be recycled or reused without the loss of quality.

 Cascading use of resources, waste recycling, internal residues recovery and recycle are actions that can

contribute to circularity of steelmaking, Steelmaking also results in useful by-products, such  as process  gases

 and ferrous  slag, which substitute natural resources in other sectors  and contribute to resource efficiency. 

Continued improvement of existing production routes e.g. recovery of waste heat,

optimization of operation using control models and expert or guiding systems,

Plant-wide Energy Management Systems

EU 6Steel products and applications for the energy sectors: Transportation of alternative gases (e.g. C02 H2,) use in

nuclear, wind, solar PV,  concentrated solar,  fuel  cells and H2, marine energy technologies.

Leaner use of raw materials: use of secondary iron (scrap), use of raw materials of

lower quality, yield improvements, recycling of societal residues, limit use of

critical raw materials

7

The 4 ULCOS breakthrough routes (ULCOS-BF, HISARNA, ULCORED and ULCOWIN/ULCOLYSIS) combine

many mitigation paths and are designed to reach very high CO2 mitigation in steel production (50 to 90%, the

latter if CCS is available). 

In the BF-BOF route: switch from carbon to alternative reducing agents such as

green H2 or electricity, The use of pre-reduced material with  CH4), better internal

use oftheir energy-containing by-products (e.g. heat recovery from slags),

CCS/CCU, integration of H2 production tech

8 The Big-Scale Initiative is persuing development and scale-up of the routes of ULCOS.Developments under the Big Scale Initiative: industry 4.0,  General concepts of

I²M (vertical integration, horizontal integration, transversal integration

Name: CSI/ECRA Technology papers 2017 Thermal efficiency: no BTT in sight

Published: 2017 Electric efficiency: no BTT in sight

Author: ECRA

Alternative fuels, raw materials and biomass: substitution of conventional fuel

with waste or biomass (implementation depends on political aspects rather than

technical)

Commissioned by: CSIReduction of the clinker content in cement. Substitutes include: granulated blast

furnace slag, fly ash, pozzolanas, limestone.

Source: Link

New binding materials. Cements based on: carbonation of calcium-silicates, pre-

hydrated calcium-silicates, belite, (belite) calcium-sulphoaluminate clinker. From a

mid-term perspective none of the new binding materials presented possess the

potential to replace cements based on Portland cement clinker on a larger scale. 

Global

CCS: post-combustion technologies (e.g. chemical absoption, membrane tech,

physical absorption, mineral carbonation, modified calcium looping process,

oxyfuel tech) and pre-combustion technologies (e.g. photosynthesis, photo-

catalytic reduction). Transport and storage unresolved. 

n.a.

CCU: enhanced oil/gas recovery (EOR), mineral carbonation, hydro-genation,

power-to-gas (PtG),  power-to-liquids (PtL), Skymine process, production of

microalgae, electrochemical or biochemical conversions.

Studies

Main messages

Aim & approach: an update of existing and future technologies for CO2 abatement and energy efficiency in the

cement sector. The analysis also calculates costs in typical future cement plants (with EU prices), conditions

and expected development. Estimations and calculations based on technical knowledge, assumptions on

further development, literature and internet data, and experts’ knowledge available in the European Cement

Research Academy.

The 7 state-of-the-art papers summarise expected development in the major technological fields (see right).

These technologies alongside others are profiled in the technology papers. 

1

Scope:

2018-2030

Stee

l

2

Cem

ent

Scope:

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Name:

Market opportunities for use of 

alternative fuels in cement plants

across the EU

1 Aim: understanding co-processing waste in cement plants as an waste-to-energy option.

Published: 2016

Author: ECOFYS

Commissioned by: Cembureau

Source:https://cembureau.eu/media/1231/ecofysreport_wastetoenergy_2016-07-08.pdf

EU

n.a.

Name:

Status and prospects of co-

processing of waste in EU cement

plants

1

Aim & approach: potential for increasing alternative fuels in 14 Cembureau EU member countries assessed with

the focus of understanding drivers and barriers to fuel substitution in the industry. For each country a case study

was made. Interviews with local experts, analysed statistical data sources, reviewed literature. 

Published: 2017 2

Current status of coprocessing and key findings: the perceived potential for further increase in fuel substitution

varies significantly between cases. It was expected that a relation exists between the maturity of the waste

management system and coprocessing rates. Potential benefits to further increase coprocessing expressed in 4

key performance indicators: avoided CO2 emissions, waste processed, fossil fuels saved and WtE

investments. 

Author: ECOFYS 3

Main drivers for coprocessing: (1) waste management policy, (2) low levels of bureucracy, (3) modernised

cement industry, (4) price (total) and price volatility of

conventional fossil fuels. 

Commissioned by: Cembureau 4Barriers to higher coprocessing: (1) unavailability of high quality waste fuels, (2) excessive bureaucracy, (3)

public unacceptance of waste combustion 

Source:

EU

n.a.

Name:Competitiveness of the European

Cement and Lime Sectors1 Aim: offer an assessment of the competitiveness of the EU cement and lime sectors. 

Published: 2017 2

Findings: regulatory and framework conditions -Climate and ETS, (access to) natural resources, energy

legislation and industrial emissions are seen as most important legislative areas by both firms and industry

associations interviewed. Climate and ETS are seen by companies as the most relevant regulatory issue.

Industries perceive potential policy changes in the ETS segment (including those post 2030) as a risk for

business operations and thus call for long-term policy stability. 

Key findings: (1) co-processing of waste widely employed but potential for further uptake. (2) More than enough

suitable waste for co-processing. (3) Large differences between member states. (4) National governments play

a key role. (5) No technical limitation at the cement plants to increase the share of alternative fuels from 36% to

95%. (6) 5% of primary raw material in clinker can be replaced by mineral ashes contained in the waste derived

fuel. (7) Willingness and ability to pay for advanced waste treatment varies per country, largely depending on

the economic situation. (8) Market distortions hamper further uptake of alternative fuels in certain member

states.

Approach: use of three case studies (Greece, Poland and Germany) with a focus on: (a) the overall potential,

(b) the benefits and (c) barriers and drivers of co-processing waste in cement plants.

Differences across MSs in terms of political treatment of co-processing. In all but two analysed MSs the main

barriers for further waste uptake were outside the cement industry (i.e. the sector is perceived as technically

ready to increase its use of alternative fuels).

CCS/CCU

2

3

5

Cem

ent

& L

ime

Cem

ent

Scope:

Scope:

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Author: ECORYS 3

Conclusions cement: 1)The EU cement sector is highly cyclical and external shocks on demand can have

substantial consequences for the sector. Access to international markets can serve cushion fluctuations of

domestic markets, but also contains a risk as facilitated trade goes both ways.

Commissioned by: n.a. 4

2) Competitiveness- risk of increased import penetration due to policy measures (e.g. targeted or blanket

energy taxes or production taxes). Stability and predictability of policy frameworks influence competitivenss. For

ETS policies, call for long-term stability (post 2030). Policy makers to actively monitor neighbouring countries

and transport costs, launch initiatives for level playing field between EU and non-EU producers and actions to

address the problem of carbon leakage. Policy makers to be attentive to regional impacts of EU policy

changes. 

Source: Link 5

3) Competitiveness of cement versus other products - policy makers should support the development of a life

cycle costing approach at the level of construction works and adhere to material neutrality. ‘Out of the box’

solutions to address CO2 emissions, enabled through dialogue and cooperation between industry and

government. 

EU 6Conclusions Lime: 1) Lime prices vary within the EU, underlining the broad product differentiation, the wide

divergence in terms of productivity, as well as limited trade intensity due to the rather low value/weight ratio. 

7

2) Competitiveness: same considerations as cement for EU-non-EU competitivenss.  Competitiveness between

EU MSs affected by regional policy measures, and proximity to outside EU competition. More pronounced

impacts of policy measures to Southern and Eastern European regions. Policy makers to be attentive to

regional impacts of EU policy changes. 

8

3) Fear for substitution of lime products not founded, despite partial substitution through e.g. chemicals.

Interdependent relationship with downstream production processes e.g. steel. Policy makers to consider the

impact on up- and downstream industries in policy making and monitor development of downstream industries. 

Name:The Competitiveness of the

European Chemicals Industry1 Trends: Declining share of the Europe-based chemicals industry in global sales.

Published: 2015 2Decrease due to declining competitiveness. Additional pressure coming from inside the EU. Highly ambitious

environmental, health and climate regulation accelerating deterioration of industrial competitiveness. 

Author: Cefic & Oxford Economics 3 Cefic supports the Commission’s objective for industrial activity to contribute 20% of GDP by 2020.

Commissioned by: Cefic 4European authorities should ensure that all EU policies and initiatives take full account of, and fit with the aim of

increasing, global competitiveness.

Source:

EU

n.a.

Name:

Chemistry 4.0

Growth through innovation

in a transforming world

1Aim & approach: A discussion of development from chemistry 3.0 to chemistry 4.0 through identification and

analysis of 30 trends important to the German chemicals industry.

Process technologies: biotechnology and utilisation of RE - application of

biological raw materials in production processes (biologization of chemistry).

Published: 2017 2

Results: many innovations in important customer industries of the chemical industry will be incremental but a

large amount of change will also be disruptive -several linked to digitalization of business models and many

linked to sustainability and circular economy.

Production of chemicals from electricity, hydrogen, and CO2

Author: VCI 3Implications of digitalisation - expected efficiency gains: R&D (30%), purchasing (5%), logistics (20%),

manufacturing (15%), sales & marketing (40%), administration (40%)

Change in product portfolios e.g. around electric engines such as battery

technology and battery recycling, lightweight materials

Commissioned by: DELOITTE 4Chemicals industry's key role in the circuar economy. 7 'R' levers: (Re)Design, Resource efficient and climate

friendly production, Return, Recycling, Recovery of energy, Residue depositing, Remove. 

Source: Link 5Recommended actions for companies and their associations: (1) set strategic goals,(2) enhance resources, (3)

seize opportunities, (4) Transform corporate culture. 

German chemicals industry Automation of manufacturing processes

n.a. to 2030

Scope:

CCS/CCU

Recommended political and regulatory conditions: (1) support digital education, (2) expand technical

infrastructure, improve data security, review data and protection rules, (3) Promote cooperation and

unbureaucratic development of platforms, (4) initiate dialogue on the necessity of and perspectives on

digitilisation, (5) understand circular economy as an integrated and open approach, (6) raise public awareness,

(7) expand innovation support, (8) review regulatory framework.

Use of big data and advanced methods of analysis for decision making e.g.

predictive maintenance, networked

logistics, and the application of concepts from virtual reality and advanced

simulation (‘in-silico’) for research.

Cefic considers the following policies important for enhancing competitveness of chemicals industry: (1) co-

ordinated, competitive energy policy, (2) responsible climate policy, (3) innovation policy, (4) regulatory stability

and consistency, (5) open markets, (6) access to raw materials, (7) addressing skills and people mobility, (8)

first class logistics.

5

6

Cem

ent

& L

ime

Che

mic

als

Scope:

Scope:

n.a.

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Name:Fertilizers and Climate Change:

Looking to the 2050CCS/CCU

Published: 2015 Hydrogen economy

Author: ECOFYS 2

For (incremental) reduction in GHGs in ammonia production: improvements in the reformer section, application

of low pressure synthesis, improved process control, process integration and motors. BTTs needed (see

technology column) but unlikely to be implemented before 2050. 

Syngas produced from biomass

Commissioned by: Fertilizer Europe 3Rapid development of hydrogen economy could change picture- policy makers need to stimulate demand side

managementElectrolysis

Source: Link 4 For reduction in GHGs in nitric acid production: use of waste heat Nuclear high-temperature electolysis

EU 5 Biggest impact from ferilizers is from use, not manufacturing. Solid State

n.a. to 2050 6Recommendations: (1) design of carbon market and climate policies post-2020, (2) implementation of demand-

side management and CCS, regulation to promote best farming practices 

Closing the fertilizer loop'- efficient use of on-farm waste and nutrient recycling

strategies

Name: Innovation in the lime sector

Published: 2018

Author: EULA

Commissioned by: EULA

Source:

EU

n.a.

Name:

The EU Petroleum Refining Fitness

Check: Impact of EU Legislation on

Sectoral Economic Performance

Published: 2015

Author: JRC-IPTS

Commissioned by: Link

Source: European Commission

EU

n.a.

Name: The Two Team Project Report Deep Eutectic Solvents

Published: 2013 Flash Condensing with Steam

Author: CEPI Supercritical CO2

Commissioned by: CEPI 100% electricity

Source: Link Steam in paper drying

EU DryPulp for cure-formed paper

n.a. Functional surface

Name:

Stakeholder's discussion paper on

"2050 Roadmap to a low carbon

bioeconomy

1Decarbonising by 80% compared to 1990 (bringing emissions to 12 Mt) while achieving 50% more added value

will require a combination of different measures. 

Energy efficiency: process improvments (incl. transition to to Industry 4.0),

investments in state-of-the-art tech.

Published: 2016 2For value creation: efficiency gains, smarter manufacturing, better data management, industry 4.0, adding more

functions to products, development of new bio-based productsFuel switch: conversion of industrial installations to low-carbon energy.

Author: CEPI Demand-side flexibility: on-site cogeneration to engage in energy market.

Commissioned by: CEPI Emerging and breakthough tech (indentified in the two team project report).

Source: Link Carbon reduction from purchased electricity. 

EU Transport improvements. 

n.a. to 2050

Fert

illiz

ers

1Aim & approach: The Two Team Project, set up by CEPI to identify BTT in the industry. 8 breakthough concepts

presented and assessed (see technologies column). The winning innovation was Deep Eutectic Solvents.

Aim & approach: future-oriented climate and energy roadmap focussing on 2 N-fetilizers: Ammonium nitrate

(AN) and Urea.

1

1

Fore

st F

ibre

(P

ulp

, Pap

er, W

oo

d)

1

The industry will need 40% more investments beyond BAU levels. Regulatory costs, risk profiles and investment

cycles need to be addressed.

Required policy shifts in 6 areas: (1) raw materials, (2) energy and climate change, (3) transport, (4) research,

(5) bioeconomy, (6) skills and education

Aim & approach: to demonstrate how the sector manages to pursue innovation, going in depth into: innovation

in quarry,  process emissions mitigation, improvements in enery efficiency, innovation in use phase, innovation

in sustainability tools, innovation in carbonation, innovation at end of life. 

See technologies list for low-carbon innovations from the study.

Aim & approach: quantitative and qualitative assessment of impact of legislation on costs and revenues of the

EU petroleum refining industry and therefore on its capacity to remain internationally competitive. Analysis of

how coherently and consistently the EU legislation for the sector works together, whether it is effective and

efficient, and whether it is associated with excessive regulatory burdens, overlaps, gaps, inconsistencies or

obsolete measures.

3

4

Scope:

Scope:

Scope:

Scope:

Ref

inin

gLi

me

Scope:

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Name:Europe’s flat glass industry in a

competitive low carbon economy1

Aim & approach: an industry vision to decarbonisation which can be achieved if supported by the right

regulatory framework. 

Soltions in glass products themselves for building, automotive and solar energy

sectors (e.g. use of insulating glazing)

Published: 2018 2The  flat  glass  industry  intends  to  deliver Performance,  Sustainability  and  the  Production Capacities

needed for Europe’s low carbon futureGlass technologies for solar energy, lighter glass in green vehicles

Author: Glass for Europe Recycling

Commissioned by: Glass for Europe

Source: Link

EU

n.a.

Name:

Critical metals in the Path towards

the Decarbonisation of the EU

energy sector

1

Aim & approach: Assessing rare metals as supply-chain bottlenecks in low-carbon energy technologies. The

study considers 17 technologies, including fuel cells, electricity storage, electric vehicles and lighting, and the re-

addressed six technologies analysed in the first study.  

Reycling of raw materials

Published: 2013 2Under forecasts of demand, Dysprosium was identified as being the most ‘at risk’, with the EU requiring over

25% of expected world supply to meet EU demand for hybrid and electric vehicles and wind turbines.

Author: JRC 3Under assessment of market and geopolitical factors, eight metals were given a high criticality rating and

therefore cassified as critical.

Commissioned by: European Commission

Source: Link

EU

n.a.

Name:

Non-ferrous Metals Manufacturing:

Vision for 2050 and Actions Needed,

JRC Science for Policy Research

1

Aim: foresight study to (1) define a long-term vision for the industry and (2) propose concrete actions that the

industry and also policy, research and other stakeholders can take to address the challenges faced by the

sector (with special attention to advanced manufacturing techniques). 

Smart materials, big data analysis, modulated production

Published: 2017 2Approach: participatory, qualitative methodology. Two workshops with representatives from the industry,

research institutions, policymakers, trade unions and stakeholders from upstream and downstream sectors

Circularity - tech to improve recycling process, to trace and capture materials post-

use, sort materials and to disassemble products

Author: JRC 3Key conclusions: vision statement stating that the industry aims at being a valued and trusted world leader in

delivering sustainable, innovative and competitive non-ferrous metal based solutions globally.

New materials e.g. new alloys and tech for importing raw materials from space or

the deep seas

Commissioned by: European Commission

Source: Link

EU

n.a. to 2050

Name:

Long-term trajectory towards a low

carbon economy in 2050 - Non

Ferrous Metals

1

Production largely electricity-intensive and large parts of the metals sector have stepped towards

decarbonisation by switching from fossil-fuel-based CO2 emitting processes to more energy efficient electric

processes (with 100% decarbonization potential for the power generation sector). The CO2 footprint is

influenced more by indirect emissions from electricity than from the direct use of carbon

Replacement of fossil fuels with alternative low-carbon fuels (e.g.

biofuels/biomass, hydrogen, synthetic fuel, alcohols)

Published: 2018 2

Shift to green electricity is dependent on: (1) availability of reliable green electricity, (2) affordable prices for

green electricity, (3) continued compensation of indirect costs since also renewable Purchase Power

Agreements contain carbon costs due to the power market characteristics. 

CCS/CCU

Author: Eurometaux 3

Companies have already made significant investments through continuous technology upgrades. Future margin

for efficiency improvements is small because metals sectors are already operating very close to their maximum

efficiency limits. Incremental technology is important

Further electrification

Commissioned by: Eurometaux 4

In an increasingly decarbonised power system, metals smelters offer opportunities for grid stabilisation and

peak attenuation. Metals smelters are contracted by TSOs due to their high electricity consumption and ability to

reduce demand at short notice.

Source:

EU

1990-2050

Procurement and stockpilling

Sustainability awareness along the value chain

Gla

ss

Trade and international cooperation

4

3Flat glass products provide energy efficiency and renewables solutions. The industry has a vision for the four

sectors where it is active: buildings, transport, RE and environmentally friendly manufacturing base.

To achieve this industry needs a Supportive European Policy Framework

Energy - tech that can tackle intermittent nature of renewable energy sources,

optimise energy efficiency, and can take advantage of waste heat recovery

Reuse of surplus heat

No

n-Fe

rro

us M

etal

s

Design and innovation -  eco-design for disassembly, recycling, remanufacture,

substitution, reduction in quanitity used (e.g. through nanotech)

Risk mitigation: the study considers ways of mitigating the supply-chain risks for the critical metals. These fall

into three categories: increasing primary supply, reuse/recycling and substitution, innovation

5 The study provides policy actions to mitigate raw materials risk for the path to decarbonisation

Four clusters of challenges identified: (1) trade and competition, (2) innovation (technological innovations are

crucial -policy has a central role to play by providing a long-term innovation- and investment-friendly support to

the industry, not only at the early stages of the research and development process, and also a call for more

flexible and adaptable regulations regarding materials classification to allow a quicker deployment of

innovations). (3) Resources (closing resource loop) and (4) business integrity and skills. 

4

For direct emissions, BTT will require significant investments, horizontal cooperation, and syngeries between

sectors, and breakthroughs in regulatory framework. 5

Scope:

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Name:

Digitalization and Energy 2017

[digitalized energy production and

impact on few industry sectors]

1 The value of digitalization in improving the efficiency of energy and material use will only increase. Industrial robots and 3D printing

Published: 2017 2Cost-effective energy savings can be achieved through advanced process controls, and by coupling smart

sensors and data analytics to predict equipment failureSmart sensors and data analytics to predict equipment failure

Author: IEA

Commissioned by:

Source: Link 1; Link 2

Not specified

n.a.

Name:

New Horizons: Future Scenarios for

Research & Innovation Policies in

Europe

1

Approach based on two scenarios: (1) A turbulent tomorrow: the 'perseverance' scenaro and (2) Transition to a

better age: the 'change' scenario. The report suggests several areas in which R&I could help find solutions to

old problems. Solutions can be split into three categories :(1) 'solutions-oreinted R&I' to find novel solutions, (2)

'understanding-oriented research' to gain knowledge on the challenges we face and (3) 'frontier research' to

make society more resilient in the long term

Complementary technologies for energy transition e.g. energy storage and smart

grid infrastructure

Published: 2017 2

Basic principles for research and innovation: (1) build resilience by developing options before, rather than after,

a crisis strikes, (2) experiment in real world settings, (3) learn from the best, (4) get the governace right -

inclusiveness and fairness as policy principles, (5) look to cities as labratories, (6) connect and collaborate

across sectors, (7) be open.    

CCS/CCU

Author: DG RTD 3Low carbon transition. The recognition of the need to transform the economy to support planetary health along a

green and jobs-friendly trajectory of growth and prosperity. Leading ultimately to a circular economyCircular economy

Commissioned by: European Commission 4

In 2030, both OECD and non-OECD countries to have resource efficient economies decoupling material

consumption from economic growth. Networked service provision at "zero marginal cost", advanced automation

and new production and consumption models. 

Nanotechnology, biotechnology and ICT technologies

Source: Link 5

The efficient use of natural resources, energy efficiency and avoidance of waste. 'Green' approaches benefit

from advances in nanotechnology, biotechnology and ICT technologies. 'Advanced materials' provide solutions

to problems caused by shortages in raw materials 

Sharing economy

EU

n.a.

Name:The Circular Economy a Powerful

Force for Climate Mitigation 1

Aim & approach: discussion of how demand side, through a more circular economy, could reduce

emissions. Analysis on steel, plastics, aluminium and cement in the EU, as well as two key supply chains-

passenger cars and buildings- and found CO2 abatement potential of 56%.

Technology that makes circular economy measures more viable e.g. advanced

sensors, automation, information technology, mobile apps

Published: 2018 2 The key conclusion: a more circular economy can make deep cuts to emissions from heavy industry. CCS

Author: Material Economics 3

Three circular strategies work together to cut EU industrial emissions: (1) materials recirculation (abatement

potential of 178 Mt CO2 per year), (2) more material-efficient products (56 Mt) and, (3) new cirular business

models (62 Mt).

Recycling technology e.g. dismantling tech, sorting tech

Commissioned by: n.a. 4

Circular economy strategies economically attractive because: (1) materials recirculation can build on high-value

production of recycled materials, (2) major value chains could reduce the amount of materials required for

product, (3) new circular business models could yield major productivity gains and co-benefits.

Sophisticated scrap market

Source: Link Digitilisation e.g. of construction (3D printing)

EU

To 2050

Leadership and concerted action needed, incl. new policy agenda. Approaches: (1) set the direction and

recognise the potential of the circular economy as a major contributor to climate targets, (2) create enablers

from publicly funded research, to infrastructure, to regulatory frameworks, (3) level the playing field to remove

incentives to waste and improve the financial case for investment in circular economy measures, (4) take

government action. 

5

Mul

tip

le In

dus

tria

l Sec

tors

Scope:

Deployment of industrial robots is expected to continue to grow rapidly, with the total stock of robots rising from

around 1.6 million units at the end of 2015 to just under 2.6 million at the end of 2019.

Technologies such as industrial robots and 3D printing are becoming standard practice in certain industrial

applications. These technologies can help increase accuracy and reduce industrial scrap

A change from ownership to sharing6

3

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