What is the objective of the "System Integration" subproject as it enters the third phase of Carbon2Chem^®?

Thorsten Wack: In the third phase, our focus remains firmly on the overarching goal of Carbon2Chem^®: contributing significantly to the success of the energy transition and reducing CO₂ emissions. During the second phase, we expanded our focus beyond the steelworks to include other industries, such as cement and lime.

In the "System Integration" subproject, we laid the groundwork so that we could investigate a range of systemic issues in the laboratory and technical center. In the third and final phase, we examine individual technologies and their interaction at the systemic level, with the goal of integrating them on an industrial scale. In doing so, we must consider that an industrial-scale plant must pay for itself within 20 to 30 years and be designed in a way that allows it to withstand the transformation process. The result should be a blueprint for building such plants.
 

How would you explain this “Transformation Path”?

Thorsten Wack: The transformation path is the process of industries such as steel and cement are undergoing to change their production methods. The goal is to reduce CO₂ emissions and operate in a more environmentally friendly manner. For instance, the steel industry is transitioning from blast furnaces, powered by coke and coal, to direct reduction plants, operated by hydrogen or green methane. This transition will not happen overnight but will take several decades. Therefore, the transformation path includes technical innovations and adjustments to production processes to achieve the desired environmental goals.
 

How do you combine and integrate previously developed technologies into plant concepts?

Thorsten Wack: We take a structured approach based on the expertise of our interdisciplinary communities. These communities consist of experts who focus on various aspects, such as simulation, life cycle analysis (LCA), and energy integration. The process begins with the aggregation of all relevant information collected to date within the framework of Carbon2Chem^®. Through this process, we develop integrated process concepts that clarify how plants can be operated using different gas sources, such as blast furnace gas, converter gas, or coke oven gas. It is important to identify how much CO₂ can be avoided depending on the plant's scale and market dynamics over the next ten to twenty years.

Another key component of our work is the economic analysis we conduct on the plants. We use advanced calculation methods and simulation techniques to thoroughly examine and quantify the functionality of the process concepts. This enables us to make reliable statements about how the plants will function later and what financial returns can be expected – aspects that are of particular interest to investors.
 

I imagine that would be quite challenging.

Thorsten Wack: That's why the “System Integration” subproject involves such a wide range of partners, from industry and universities to asset managements like Thyssenkrupp Vermögensverwaltung.

In my view, one of the biggest challenges is integrating the various system components. Converting CO₂ from steel mills into basic chemicals requires more than developing individual technologies, such as a methanol reactor. Instead, we must consider the entire value chain, including market conditions and its impact on the global market. This is why it is crucial that we collaborate with the partners involved to consider the technical aspects as well as the interactions with the environment and market.
 

How do you approach this in practice? Do you rely on artificial intelligence as well?

Thorsten Wack: In the third phase of Carbon2Chem^®, we rely on the tools developed in the first two phases. They were designed specifically for life cycle assessment (LCA) and its integration into operating concepts. These tools will enable us to respond dynamically to the availability of CO₂ and green hydrogen, allowing us to ramp up or down plants as needed.

Our approach requires time-based analysis, in which we monitor input and output data, as well as CO₂ consumption, on an hourly basis. We combine dynamic simulations with LCA methods to evaluate the sustainability and efficiency of our concepts.

Artificial Intelligence (AI) is an important aspect of this process. We have begun using the findings from the first two phases to train a multimodal large language model. This model will help us develop and optimize operating concepts under various conditions. It is important to note that the larger the training base, the more accurate and useful AI will be.
 

What will happen to all these tools once the Carbon2Chem^® project is finished?

Thorsten Wack: At the end of the joint project, the carbon dioxide capture and utilization (CCU) solutions developed will be made available via a technology platform, along with so-called "CCU ecosystems" that support the implementation of the research results. While our tools will contribute significantly to these results, they will not be published on the platform themselves. However, they can be integrated into other projects, thereby strengthening Fraunhofer UMSICHT's scientific orientation and reputation.
 

What exactly is a “CCU Ecosystem”?

Thorsten Wack: It refers to the interaction and integration of various technological components that convert CO₂ into valuable chemical products for usage as raw materials. Different industries have specific requirements and challenges that call for different approaches.

For instance, the feasibility of constructing a large-scale methanol plant depends on the availability of reliable CO₂ and hydrogen infrastructure. In a CCU ecosystem, various technological components work together at different locations to efficiently capture, purify, and introduce CO₂-containing gases into the production process. This integrated system creates a comprehensive value chain that extends to the market and enables the sustainable use of CO₂.
 

Finally: What is the key to success for Carbon2Chem^®?

Thorsten Wack: The key to success at Carbon2Chem^® is the close collaboration and integration of various subprojects throughout all three phases. These subprojects do not operate in isolation but rather pursue jointly defined goals. This has resulted in remarkable and constructive cohesion over the years. An important aspect is the trust between the partners, combined with an unusual project structure that promotes the effective integration of partial results.

Additionally, financial support from the Federal Ministry of Research, Technology, and Space motivates all partners to collaborate toward these goals. This collaborative approach is crucial to Carbon2Chem^®'s overall success and enables us to develop innovative CO₂ utilization solutions.