TPT4CCUS: Feasibility study on the use of CCU/CCS technologies in thermoprocessing, with a particular focus on the use of renewable carbon carriers to further reduce CO2 emissions
Study for the Research Association for the Research Association of Industrial Furnace Manufactures (FOGI) e.V., 1 January 2025 to 30 November 2025
Project description
Despite the growth of renewable energy and widespread efforts to phase out fossil fuels in many industrial processes, it will not be possible to completely avoid the greenhouse gas carbon dioxide (CO2). The reduction, capture, and storage of CO2, as well as the establishment of an effective CO2 circular economy—known as carbon management—has become a central issue for society, politics, and industry. The Intergovernmental Panel on Climate Change (IPCC) views carbon management as a necessary step toward achieving the Paris Climate Goals. The German federal government and the EU have also presented plans for strategies. Furthermore, the topic is anchored in the strategic research and innovation agenda and, consequently, in future funding programs such as Horizon Europe.
The machine and plant engineering sector, and in particular companies in the field of industrial furnace manufacturing and thermoprocess technology, are affected by this in two ways: first, as suppliers and solution providers for energy-intensive plants, for example for the steel or non-ferrous metals industry; and second, as users of energy-intensive plants in their own manufacturing processes. It is therefore of central importance to analyze and quantitatively assess the potential of thermoprocess technology and industrial furnace construction against the background of the development of a national, European, and international carbon management strategy. The goal is not to continue operating conventional fossil-fuel-based thermal processes in the long term. Rather, by utilizing renewable carbon sources, the aim is to establish new sustainable process chains—such as CO2 capture and utilization for chemical processes—in line with the principles of a circular economy. Furthermore, combustion should take place with virtually no emissions of pollutants.
Project goals
As part of this study, a technological analysis of carbon capture methods was conducted, and their potential applications for exemplary processes in thermal processing technology were examined. The focus was on evaluating energy and resource efficiency using mass and energy balances, conducting an environmental assessment, and analyzing the impact on the economic viability of process and plant technology. The analysis was conducted quantitatively using selected case studies, which were developed in collaboration with a project committee. An analysis of the political and economic framework conditions was also performed for contextualization. The results were also compared with other strategies for CO2-neutral process heat generation (electrification, hydrogen) and form the basis for deriving recommendations for action for companies in the industrial furnace construction and thermal process engineering sectors.
The study classified the four CO2 capture technologies—oxyfuel, post-combustion with amine scrubbing, carbonate looping, and pre-combustion (biohydrogen)—based on their impact on the thermal processing plant, additional equipment and energy requirements, current state of experience, and further research needs. Overall, all concepts demonstrate significant energy and investment potential, with the integration of process waste heat and demonstrator-based studies identified as key next steps.
Project participants
Further Information
Contact
Katharina Rothhöft, M.Sc.
+49 241 80–29541
Felix Kaiser, M.Sc.
+49 241 80–25943
Fundings
This study was funded by the Research Association of Industrial Furnace Manufactures (FOGI) e.V.