With the energy transition, we are moving towards a CO2-neutral economy in the Netherlands. This transition must also occur in brownfields – existing industrial environments where business continuity and process technological (im)possibilities play a role. In this blog: how to easily adapt existing factories.
Currently, there is a lot of discussion about making the process industry more sustainable. Consider Tata Steel's ambitions to replace a coke plant with a facility that can produce steel using green hydrogen. Elsewhere in the manufacturing industry, alternative raw materials are also being explored. TU Delft has launched a research program looking into electric refining, which could enable a chemical industry without oil.
Sustainability of the Process versus Energy Supply
These discussions and research predominantly concentrate on transforming the primary process. They focus on how the production of, for example, steel, fuels, paint, and medicines can become a closed loop, where all raw materials are reused. A fascinating challenge, the solutions of which can have a tremendous positive impact on the environment, but also significant consequences for the company's own operations.
Simultaneously, there is a transition that need not be as drastic: the energy transition. This involves reducing CO2 emissions by improving the energy supply. Because the process industry has a relatively high energy demand, a substantial difference can be made with relatively little effort, even in existing factories.
Visualising the Energy Transition — The Onion Model
To illustrate the difference between making the process sustainable versus making the energy supply sustainable, we look at the onion model. This is a model for conducting heat studies based on Pinch technology. In the onion model, you see multiple layers, like you do in a sliced onion.
At the centre of the onion is the process: the chemical reaction. In the next layer, materials are separated, and heat is reused with a network of heat exchangers. What remains are by-products and residual heat. A heat pump allows this residual heat to be reused, saving utilities. In the outermost layer, we find the utilities: everything needed to keep the processes in the inner layers running, such as the supply of heat and cooling water. This is also known as the energy supply.
A low-threshold energy transition? This can be achieved by simply reusing residual heat and making utilities more sustainable. The quick wins are in these ‘onion layers.’
Solutions for a Low-Threshold Energy Transition
What are the concrete solutions for energy supply found in these outer onion layers? This includes deploying:
- Electrolysis/hydrogen
- Industrial heat pumps
- Electric boilers
- Electrification
- Upgrading existing electrical machines
- District heating
- A Rankine cycle
- Heat exchangers
Implementing the above technologies not only contributes to the energy transition but also offers advantages for the organisation itself. For example, less dependence on energy suppliers and fluctuating rates, and a lower energy bill. By playing with process intensity and making smart use of electricity surpluses, energy consumption can even become part of the business model.
Which Innovation Suits Best? Research It with an Energy Transition Master Plan
Especially for existing factories, it can be a puzzle to choose the most suitable energy innovations. Considerations must be made for the production process, specific dynamics, and maintenance periods. Continuity is paramount. To make the right choices within this framework of (im)possibilities, a thorough plan is necessary. How best to approach this? Our new white paper on the energy transition master plan for the process industry will be released after summer break. Sign up now to be the first to receive it! Sign up now to be the first to receive it!
Would you like to discuss the possibilities for your brownfield environment? Contact Serdar Erdag.
For more information about KH Engineering: https://www.khe.eu/en/new-energy/
The industry faces a major challenge. Emissions must be rapidly reduced and all production must be climate-neutral by 2050. At the same time, the price of energy and raw materials is rising and a CO2 tax leads to higher production costs. So things must be done differently. But how can you best achieve sustainability without forcing factories to close? The New Energy & Infrastructure group within KH Engineering advises on how to change technical processes to save energy, reduce emissions and produce profitably in a demanding social environment.