The webinar demonstrates how electromagnetic processing of materials (EPM) provides significant opportunities for saving primary energy and reducing carbon emissions in industrial thermal processes. Potentially electricity can replace up to 100% of other energy carriers currently used for process heat. For the time horizon from now to the year 2050 transition scenarios are developed and described where the industrial processes are gradually switched from the actual situation to a situation with 100% electrically operated processes. As the average primary energy factor (PEF) gradually decreases from 2.5 currently, to 1 for a 100% renewable electricity system, the benefits of EPM will gradually increase. For each step in the development of the PEF the annual primary energy savings and annual reductions in greenhouse gas emissions will be described.

1. Electromagnetic Processing of Materials
in European Industry
Webinar 23 January, 2013
Technologies for the Electromagnetic Processing of
Materials - Energy and Carbon savings
E. Baake, B. Ubbenjans,
Institute of Electrotechnology, Leibniz University of Hanover,
Hanover, Germany
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

2. Outline
 Introduction, content and aim
 Primary energy factors & CO2-emission factors
 Energy consumption of the European industry (EU27)
 Three different transition scenarios
 Iron & steel industry
 Non-ferrous metal industry
 Chemical industry
 Glass, pottery & building materials industry
 Paper & printing industry
 Summary
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

3. Electromagnetic Processing
of Materials (EPM)
- examples -
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

4. Introduction and background
 Electromagnetic processing of materials (EPM) provides
significant opportunities for saving primary energy and reducing
carbon emissions in industrial processes.
 The use of electricity for industrial thermal processes has a final
energy share in average of around 10% in Europe (EU-27).
 Electricity has the potential to replace up to 100% of other
energy carriers used for process heat.
 The average primary energy factor gradually decreases from
2.5 currently, to a value between 0 and 1 for a 100% renewable
electricity system.
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

5. Content and aim
 Aim of this work is the demonstration of the scope for energy &
carbon saving in the EU through the use of electromagnetic
processing of materials (EPM).
 The primary energy factor and CO2-emission factor for
electricity has to be estimated year by year till 2050.
 From now to the year 2050 transition scenarios should be
investigated and compared.
 The most energy intensive production processes are switched
from the actual situation to a situation with up to 100%
electrically operated industrial processes.
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

6. Primary energy factors (PEF)
PEF for fossil energy PEF for electrical energy
Energy Carrier Primary energy factor
Hard coal 1,071811361
Coke 1,114827202
Lignite 1,038421599
Petroleum products 1,095290252
Natural gas 1,072961373
 PEF for fossil energy can be estimated as constant in the future
 PEF for electrical energy depends on energy mix
 PEF is based on a forecast of the European gross electricity generation
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

7. CO2-emission factors
Energy carrier CO2 –emission factor
[g/kWh]
Hard coal 406
Coke 473
Lignite 413
Petroleum products 301
Natural gas 227
 CO2-emission factor for fossil energy can be estimated as constant in the future
 CO2-emission factor for electrical energy depends on energy mix
 CO2-emission factor is based on a forecast of the European gross electricity
generation
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

8. Final energy consumption of the
European industry (EU27) in 2009
in
GWh
Reference: Eurostat 2011 (Sum: 3,133,762 GWh)
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

9. Share of the considered final energy
demand of the five industrial branches
Calculated final Final energy
Industry
Branch energy demand in demand of the Share
sector
2009 in GWh branch in GWh
Iron & steel Steel 434,923
Grey iron 10,972
Sum 445,904 514,848 87 %
NF metals Aluminum 2,774
Sum 2,774 103,681 3%
Chemical Plastic 110,500
Sum 110,500 585,896 19 %
Glass, pottery &
Glass 55,500
building materials
Roof tile 10,493
Brick 28,976
Cement 289,907
Lime 36,400
Sum 421,275 424,832 99 %
Paper & printing Paper 200,299
Sum 200,299 384,116 52 %
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

10. Three different scenarios
100 % electrical processes
 The reference scenario
implies no switching from
fossil fuel heated processes
Shock scenario
Share of electrical processes
to electrical processes
 The linear scenario
assumes a linear increase
of the share of electrical Linear scenario
processes up to 100% in the
year 2050
 The so-called shock
scenario implies an increase Reference scenario
from the current situation to
100% electrical processes
between 2020 and 2025
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

11. Final energy carrier in the European
iron and steel industry in 2009
Reference: Eurostat (Sum: 514,848 GWh)
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

12. Steel production in Europe (EU-27)
There are two principle routes of steel production
1 2
Iron ore Scrap Iron ore
Blast furnace: Midrex Process:
Raw iron Direct reduced iron
Oxygen blown Electric arc
converter furnace
78 Mio tons 61 Mio tons
56 % Steel production in 2009: 44 %
130 Mio tons
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

13. 1st steel production route (classical route) (1)
The first step is the production of
raw iron with the blast furnace
 For the fabrication of 1 ton of
crude iron a typical blast furnace
needs:
• 650 kg of iron ore
• 907 kg of sinter
• 475 kg of coke
• 800 MJ of electrical energy
• 2.5 kg of scrap
18 % of the blast furnace gas is
recovered for the production of
coke
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

14. 1st steel production route (classical route) (2)
 The liquid iron is transformed
into steel in an oxygen blown
converter
 Oxygen is pumped through the
melt to reduce the carbon
 The oxygen converter needs for
1 ton of steel:
• 856 kg of raw iron
• 65 m3 of oxygen
• 287 kg of scrap
• 29 kg carbon
• 3 kg coke
• 82 kg lime
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

15. 2nd steel production route (1)
 The electric arc furnace can be
charged with scrap or direct
reduced ore
 The volume is melted down
through a powerful electric arc
 For the production of 1 ton of
steel the arc furnace needs:
• 1080 kg of raw material
• 1500 MJ of electrical energy
• 30 m3 oxygen
• 14 kg coke
• 38 kg lime
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

16. 2nd steel production route (2)
 Today nearly all electric arc furnaces are
operating with steel scrap
 The amount of available steel scrap will
increase slidely
 The production of direct reduced ore has
to be enlarged
 The production of 1 ton of direct reduced
iron needs approx.:
• 1500 kg ore,
• 376 m3 of natural gas
• 486 MJ of electrical power
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

17. Iron & steel industry / steel industry
Save of final energy
By using the linear switching
scenario up to 1.3 million
GWh of final energy can be
saved.
By using the shock scenario
1.8 million GWh of final
1.8 Mio GWh
energy can be saved.
1.3 Mio GWh
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

18. Iron & steel industry / steel industry
Save of primary energy
By using the linear switching
scenario up to 5,680 PJ of
primary energy can be
saved.
By using the shock scenario
7,850 PJ of primary energy
can be saved. 7,850 PJ
5,680 PJ
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

19. Iron & steel industry / steel industry
Save of CO2-emission
By using the linear switching
scenario up to 1,470 million
tons of CO2-emission can be
saved.
By using the shock scenario
up to 2,040 million tons of
CO2-emission can be saved. 2,040 Mio tons
1,470 Mio tons
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

20. Iron & steel industry / cast iron industry
Cast iron industry
Production in 2007:
13 million tons
Melting processes:
Medium frequency induction crucible furnace (50 %)
520 kWh/to electrical energy
48 kWh/to oxidation losses
74 kWh/to carburization
Hot blast cupola furnace (50 %)
900 kWh/to coke
20 kWh/to gas
30 kWh/to electrical energy
143 kWh/to oxidation losses
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

21. Iron & steel industry / cast iron industry
Save of final energy
By using the linear switching
scenario up to 53,833 GWh
of final energy can be saved.
By using the shock scenario
74,841 GWh of final energy
can be saved. 74,841 GWh
53,833 GWh
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

22. Iron & steel industry / cast iron industry
Save of primary energy
By using the linear switching
scenario up to 135.6 PJ of
primary energy can be
saved.
By using the shock scenario
184.5 PJ of primary energy
184.5 PJ
can be saved.
135.6 PJ
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

23. Iron & steel industry / cast iron industry
Save of CO2-emission
By using the linear switching
scenario up to 48.1 million
tons of CO2-emission can be
saved.
By using the shock scenario
up to 66.6 million tons of CO2- 66.6 Mio tons
emission can be saved.
48.1 Mio tons
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

24. Non-ferrous metal industry / aluminum
Aluminum industry
Production of casted aluminum in 2009:
1.96 million tons
Melting processes:
Induction channel furnace (8 %)
415 kWh/to electrical energy
200 kWh/to combustion losses
Gas fired furnaces (92 %)
712 kWh/to natural gas
775 kWh/to combustion losses
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

25. Non-ferrous metal industry / aluminum
Save of final energy
By using the linear switching
scenario up to 32,137GWh of
final energy can be saved.
By using the shock scenario
44,678 GWh of final energy
can be saved.
44,678 GWh
32,137 GWh
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

26. Non-ferrous metal industry / aluminum
Save of primary energy
By using the linear switching
scenario up to 105 PJ of
primary energy can be
saved.
By using the shock scenario
155 PJ of primary energy can
145 PJ
be saved.
105 PJ
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

27. Non-ferrous metal industry / aluminum
Save of CO2-emission
By using the linear switching
scenario up to 13 million tons
of CO2-emission can be
saved.
By using the shock scenario
up to 18 million tons of CO2-
18 Mio tons
emission can be saved.
13 Mio tons
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

28. Chemical industry / plastic industry
Plastic industry
Production of plastics in 2007:
65 million tons
Specific use of energy:
1.7 MWh/to
Energy carrier:
61 % electrical energy
30 % gas
9 % oil
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

29. Chemical industry / plastic industry
Save of final energy
By using the linear switching
scenario up to 0 GWh of final
energy can be saved.
By using the shock scenario
0 GWh of final energy can be
saved.
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

30. Chemical industry / plastic industry
Save of primary energy
By using the linear switching
scenario up to 1,250 PJ of
primary energy have to be
spend additionally.
By using the shock scenario
1,790 PJ of primary energy
have to be spend
additionally.
-1,250 PJ
-1,790 PJ
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

31. Chemical industry / plastic industry
Save of CO2-emission
By using the linear switching
scenario up to 103 million
tons of CO2-emission can be
saved.
By using the shock scenario
up to 139 million tons of CO2-
emission can be saved. 139 Mio tons
103 Mio tons
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

32. Glass, pottery & building materials / glass industry
Glass industry
Production of glass in 2007:
37 million tons
Specific use of energy:
1.5 MWh/to
Energy carrier:
20 % electrical energy
34 % gas
46 % oil
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

33. Glass, pottery & building materials / glass industry
Save of final energy
By using the linear switching
scenario up to 0 GWh of final
energy can be saved.
By using the shock scenario
0 GWh of final energy can be
saved.
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

34. Glass, pottery & building materials / glass industry
Save of primary energy
By using the linear switching
scenario up to 1,258 PJ of
primary energy have to be
spend additionally.
By using the shock scenario
1,806 PJ of primary energy
have to be spend
additionally.
-1,258 PJ
-1,806 PJ
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

35. Glass, pottery & building materials / glass industry
Save of CO2-emission
By using the linear switching
scenario up to 129 million
tons of CO2-emission can be
saved.
By using the shock scenario
up to 175 million tons of CO2-
emission can be saved. 175 Mio tons
129 Mio tons
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

36. Glass, pottery & building materials / cement ind.
Cement industry
Production in 2008:
255.4 million tons
Specific use of energy:
867 kWh/to
Energy carrier:
11.4 % electrical energy
0.9 % gas
2.7 % oil
41.2 % petcoke
23.6 % coal
4.3 % lignite
15.9 % waste
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

37. Glass, pottery & building materials / cement ind.
Save of final energy
By using the linear switching
scenario up to 0 GWh of final
energy can be saved.
By using the shock scenario
0 GWh of final energy can be
saved.
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

38. Glass, pottery & building materials / cement ind.
Save of primary energy
By using the linear switching
scenario up to 7,182 PJ of
primary energy have to be
spend additionally.
By using the shock scenario
10,312 PJ of primary energy
have to be spend
additionally.
- 7,182 PJ
- 10,312 PJ
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

39. Glass, pottery & building materials / cement ind.
Save of CO2-emission
By using the linear switching
scenario up to 1,604 million
tons of CO2-emission can be
saved.
By using the shock scenario
up to 2,205 million tons of
CO2-emission can be saved. 1,604 Mio tons
2,205 Mio tons
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

40. Paper & printing industry / paper industry
Paper industry
Production in 2009:
87.1 million tons
Specific use of energy:
2.7 MWh/to
Energy carrier:
30 % electrical energy
42 % gas
2 % oil
12 % hard coal
14 % others
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

41. Paper & printing industry / paper industry
Save of final energy
By using the linear switching
scenario up to 0 GWh of final
energy can be saved.
By using the shock scenario
0 GWh of final energy can be
saved.
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

42. Paper & printing industry / paper industry
Save of primary energy
By using the linear switching
scenario up to 3,815 PJ of
primary energy have to be
spend additionally.
By using the shock scenario
5,470 PJ of primary energy
have to be spend
additionally.
- 3,815 PJ
- 5,470 PJ
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

43. Paper & printing industry / paper industry
Save of CO2-emission
By using the linear switching
scenario up to 374 million
tons of CO2-emission can be
saved.
By using the shock scenario
up to 508 million tons of CO2-
emission can be saved. 374 Mio tons
508 Mio tons
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

44. Summary I
A switching from fuel operated processes to a production applying
mainly electrical operated processes offers big potentials for saving
CO2-emission.
But for saving of energy it is necessary to improve or change the
process not only the energy carrier.
By using the linear switching scenario in all the presented case studies
• 1.38 million GWh of final energy,
• - 9690 PJ of primary energy and
• 3.97 billion tons of CO2-emission can be saved in sum.
By using the shock scenario it is possible to save
• 1.92 million GWh of final energy,
• -14210 PJ of primary energy and
• 5.46 billion tons of CO2-emission.
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

45. Summary II
 The primary energy factor and CO2-emission factor for
electricity are analyzed and estimated year by year till 2050.
 From now to the year 2050 transition scenarios are developed,
where three transition scenarios are compared in detail.
 Part of the most energy intensive production processes are
switched from the actual situation to a situation with 100%
electrically operated industrial processes.
 A switching from fuel operated industrial thermal processes to a
production applying mainly EPM technologies offers big
potentials for saving of energy and CO2-emission.
 For saving of energy it is necessary to increase the efficiency of
the production process not only to change the energy carrier.
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake

46. Thank you for your
attention!
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EPM Technologies: Energy and Carbon savings, 23 Jan. 2013, Webinar, E. Baake