Transformation Plan for Schaefer Kalk
Support on the way to GHG neutrality by calculating various energy supply concepts
Together with sustainable AG, FfE is developing a transformation plan (formerly transformation concept) in accordance with BAFA Module 5 for the Hahnstätten and Steeden sites of Schaefer Kalk.
Motivation
In order to achieve the climate targets of the Federal Republic of Germany and the EU ETS, the industrial sector must also achieve GHG neutrality. Lime production in particular not only causes energy-related emissions from the use of fossil fuels, but also so-called process emissions that arise directly from the raw materials used (limestone). Companies in the lime industry therefore face particularly great challenges when it comes to developing transformation plans for CO₂ avoidance.
Project Objectives
Transformation plans offer the opportunity to develop paths to GHG neutrality and evaluate them techno-economically. The aim is to compare the various options and thus create the basis for decision-making for further corporate strategy. The transformation plans must achieve a 40% reduction in emissions within 10 years and GHG neutrality by 2045.
Project structure
The project first records the current status of the site in order to subsequently derive and calculate various transformation paths.
The actual state is mapped by a GHG balance of Scope 1, 2 and 3 emissions. This step was carried out in this project by sustainable AG.
The development of the target state and the associated transformation pathways towards it is being handled by FfE. Finally, a selected transformation path will be translated into a concrete roadmap.
Methodology
The FfE’s approach to developing and calculating transformation pathways follows the ‘first savings, then transformation’ approach and is described in detail in this series of articles.
In summary, this approach means that energy efficiency potentials are first identified and the corresponding energy, CO₂ and cost saving potentials are calculated.
The remaining consumption and emissions are then transformed through disruptive measures. These disruptive measures are selected not only on the basis of FfE expertise, but also with the involvement of all relevant company divisions in a benefit analysis workshop. The specific knowledge available in the companies is collected and incorporated into the transformation plan. The measures best evaluated in these workshops are then incorporated into coherent, time-phased overall concepts.
Results
The Hahnstätten and Steeden sites can achieve GHG neutrality with the transformation paths shown. The project identified the necessary measures and calculated the costs incurred and the development of energy consumption and emissions.
The greatest savings potential will initially be achieved by setting up and expanding a heating network to utilise waste heat from the lime kilns.
A concept focussing on biomass utilisation and one focussing on the use of hydrogen were developed for Schaefer Kalk as chronologically resolved overall concepts. Both concepts also took into account various CO₂ capture processes, which are absolutely necessary in order to also reduce the raw material-related process emissions. In a final roadmap for each concept, the measures to be implemented are localised in terms of time.
GHG neutrality at the Steeden and Hahnstätten sites will be achieved in the calculated concepts in 2042 at the earliest, when CO₂ capture is put into operation. The concepts take into account the processes of amine scrubbing, pressure swing adsorption (PSA) and oxyfuel combustion with subsequent (cryogenic) liquefaction. The concepts are still subject to regulatory developments (e.g. with regard to biomass) and infrastructural requirements (e.g. the availability of hydrogen or a CO₂ infrastructure). These aspects were also discussed in detail with the client during the development of the transformation pathways.
The results form the basis of the decarbonisation roadmap published by Schaefer Kalk following the project (Roadmap Decarbonisation: Schaefer Kalk).
Project partner
sustainable AG
Funding
Funding as part of EEW BAFA Module 5.
Weitere Informationen
- Transformationspläne
- Beitragsreihe Transformationspläne: Allgemeine Informationen und Erstellung
- Beitragsreihe Transformationspläne: Erstellung von praxisnahen Transformationsplänen durch die FfE
- Beitragsreihe Transformationspläne: Ergebnisse und Herausforderungen bei der Erstellung von Transformationsplänen