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

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.