Analysing the feasibility of industrial decarbonisation pathways through electrification and zero carbon fuel (ZCF) applications

Industrial decarbonisation is one of the most significant hurdles as we move towards a global net-zero CO2 emissions target. Processes requiring high temperatures and heavy-duty transport are major complications, with cost and feasibility of implementation of zero carbon methods often significant barriers, especially for medium sized or smaller businesses. This study shows that decarbonisation of business processes through electrification as well as on-site green ammonia generation, is possible and can be profitable for this scale of company. Mühlendorfer Kreidefabrik, used as a case study, is an Austrian chalk processing factory that emits approximately 4680 tonnes of CO2 per year whilst spending EUR664,000 on energy. Different decarbonisation scenarios were investigated, based on the general concepts of electrification and zero-carbon fuel (ZCF) generation. The study leveraged simulation algorithms in conjunction with past usage data of the company in order to model supply and demand in future years. 4.7 MW of solar PV panels as well as one 3 MW wind turbine are required in a pure electrification scenario. Including the replacement cost of fossil-fuel by electrified equipment and an estimated lifetime of 20 years, this system is expected to cost ~EUR512,000 annually. A larger electricity generating system of 13.7 MW solar PV panels and one 3 MW wind turbine is required in a ZCF scenario, along with a 3.9 MW alkaline electrolyser connected to an air separation unit and Haber-Bosch equipment. This system will produce ~1887 t of green ammonia per year, sufficient to replace both natural gas and Diesel currently used in the factory, requiring only adaptation of current plant and machinery instead of replacement. Costing ~EUR714,000 annually, this option is more expensive, however has further advantages in minimising interference in factory operations. This pathway seems also preferable due to the uncertainty in availability of a pure electrified solution even with the extra costs.