industrial value chain a bridge towards a carbon …(cement stone) product can be used as filler in...
TRANSCRIPT
7 September 2018
Industrial Value Chain
A Bridge Towards a Carbon Neutral
Europe
ADDENDA
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.
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
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%
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
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
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.
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.
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.
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.
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)
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)
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.
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
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]
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.
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]
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
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
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
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)
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%
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
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
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
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%
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
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
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:
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:
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.
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:
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:
4
Scope:
Scope:
Scope:
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
Scope:
Scope:
4