1 of 8

Electrification and Decarbonization Solutions for Industry�High-level Perspectives on Chemicals and Industrial Sectors

Amit Sarkar

Resident Visiting Scientist (Stanford University)

Corporate Research Scientist for North America (TotalEnergies SE)

​

April 7, 2022

2 of 8

Energy use and emissions from industrial sector

Electrification and Decarbonization Solutions for Industry – Review of the Common Issues and Potential Solutions – SEA Workshop – April 5-7, 2022

2

  • 44% of industrial energy consumption is in the form of fuel1
  • accounts for 19% (w/o indirect emission from imported of heat or electricity) of global emission2
    • Feedstock: conditioning (e.g., calcination), energy carrier (e.g., SMR), carbon source (e.g., naphtha cracker)
      • Hard to decarbonize inherently without disruptive novel technologies
    • High-temperature (> 500 °C) heat: potentially most attractive target for electrification
    • Low/mid-temp heat: decarbonize via energy efficiency improvement and/or electrification

3 of 8

Decarbonizing chemicals manufacturing: SCALE and….

Electrification and Decarbonization Solutions for Industry – Review of the Common Issues and Potential Solutions – SEA Workshop – April 5-7, 2022

3

  • Chemical industry consumes 28% of industrial and 10% of global energy: mostly fossil-sourced3
    • use as carbon feedstock (58%) or to generate process energy (42%)
    • current use of electricity: ~ 22% (10 EJ or 2.8 PWh)
  • CCU: potential to decouple from fossil resources and reduce emission up to 3.5 Gt CO2/yr by 20303
    • will require 18.1 PWh of low-carbon electricity (55% of the projected global electricity production in 2030)!!!
  • Unique techno-economic challenges to decarbonize chemicals manufacturing sector
    • changing feedstock might require new process, e.g., SMR of NG for ammonia vs. water electrolyzer
    • adaptation and scale-up of alternative furnace (electric or hydrogen) for very high temperature (>1000 °C) heat: burner design, fuel mixing, safety consideration
    • any change in part of the highly integrated process chain have will require changes to other parts of the process
    • requires continuous supply of energy at scale: sudden interruption can cause havoc
    • huge size/scale and long life-time (40+ years) of facilities: require time- and capital-intensive retrofit
    • relatively low profit margin and global competition for low-cost production: little incentive to decarbonize

4 of 8

Direct electrification of heating in industrial sector

Electrification and Decarbonization Solutions for Industry – Review of the Common Issues and Potential Solutions – SEA Workshop – April 5-7, 2022

4

  • High/very-high efficiency, precise, faster response, stable, high-power density, greater depth of penetration
    • High TRL options: electric boiler, electric arc furnace, heat-pump (mid/low-T), microwave drying, mechanical vapor recompression, membrane separation
    • Low TRL developments: high-T heat pump, plasma kiln and furnace, plasma heating or direct electrical heating of ore, membrane separation for olefins, electro-catalytic synthesis,, electrowinning and direct hydrogen reduction, electro-magnetic heating (EMH) technologies (induction, radio, MW, IR, UV)

​

​

​

Hasanbeigi et. al. (2021), Electrifying U.S. industry: A technology- and process-based approach to decarbonization, Global Efficiency Intelligence-David Gardiner & Associates-Renewable Thermal Collaborative

    • EMH technologies potentials:
      • new paradigm in high-efficiency catalytic processes: high temperature gradient in a relatively short distance (mm range)
      • high-penetration depth
      • precise heating

Credit: Dr. Shaffiq Jaffer

5 of 8

Indirect electrification using hydrogen: pay attention to efficiency!

Electrification and Decarbonization Solutions for Industry – Review of the Common Issues and Potential Solutions – SEA Workshop – April 5-7, 2022

5

  • Hydrogen produced using carbon-free electricity is used as natural gas substitute in thermal processes
  • ~40% loss of electric energy input to electrolyser to get H2 @ 700 bar!4
    • power generation using hydrogen as vector: requires scenario specific analysis to qualify

Credit: Dr. Shaffiq Jaffer

6 of 8

Electrification of industrial sector: demand & supply scenario

Electrification and Decarbonization Solutions for Industry – Review of the Common Issues and Potential Solutions – SEA Workshop – April 5-7, 2022

6

  • Share of electricity in industrial energy mix: 21%
    • complete electrification energy resources will require supplying 65% of current energy use as C-neutral electricity
    • Requires major investment and infrastructure to meet potential demand of C-neutral electricity
      • need pragmatic approach to prioritize electrification target and develop technology solution

​

Credit: Dr. Philip Llewellyn

7 of 8

Decarbonizing industrial sectors: “menu” of options

Electrification and Decarbonization Solutions for Industry – Review of the Common Issues and Potential Solutions – SEA Workshop – April 5-7, 2022

7

Alternative Feedstock

    • Use non-fossil carbon source, e.g., bio-oil/gas/mass, captured CO2
    • Use carbon-free hydrogen, e.g., replace NG to decarbonize ammonia production

Energy Efficiency

    • Improving EE will reduce energy use and resulting emissions

Electrification of Heat

    • switch to furnaces, boilers and heat pumps that run on carbon-neutral electricity
    • new production process with electrification of heat, e.g., electric cracker with e-furnace & compressor, plasma kilns

Disruptive

Process

    • novel low-C technologies to replace current processes, e.g., high-T heat pump/furnace or plasma assisted reforming, electro-catalytic synthesis of olefins and alcohols; microwave or plasma assisted pyrolysis and drying, plasma or direct electrical heating of ore, direct hydrogen reduction, IR curing

CO2 Capture

    • Capture from process emission: storage or use as source of carbon in circular carbon-economy

8 of 8

References

Electrification and Decarbonization Solutions for Industry – Review of the Common Issues and Potential Solutions – SEA Workshop – April 5-7, 2022

8

  1. Roelofsen et al. (2020), Plugging in: What electrification can do for industry, McKinset & Company (2020).
  2. Rissman et al. (2020), Technologies and policies to decarbonize global industry: Review and assessment of mitigation drivers through 2070, Applied Energy, 266, 114848.
  3. Kätelhön et al. (2019), Climate change mitigation potential of carbon capture and utilization in the chemical industry, PNAS, 116 (23), 11187.
  4. Burkhardt et al. (2015), Hydrogen mobility in electrical grids subjected to (high) intermittency – An assessment of environmental impact, World Hydrogen Technology Convention, Sydney.

Thank you!

Acknowledgement

Dr. Shaffiq Jaffer, Vice President Corporate Science & Technology Projects, TotalEnergies SE

Dr. Philip Llewellyn, CCUS R&D Program Manager, TotalEnergies SE