Anna Malakhova-Lehe studied thermal energy systems in industry in Moscow and continued her scientific career in Germany, specialising in renewable energy systems. Before joining the Competence Centre on Climate Change Mitigation in Energy-Intensive Industries (KEI) (Kompetenzzentrum Klimaschutz in energieintensiven Industrien) in 2022, she worked for more than six years on energy supply issues in floating architecture at BTU Cottbus-Senftenberg and as a planning engineer for TGA and energy concepts at Integral Projekt & Co KG GmbH in Cottbus. There she was involved in important national and international projects to increase energy efficiency.
1. Thank you very much, Mrs Malakhova-Lehe, for taking the time for this interview. As an expert in think tanks and strategic projects at the Competence Centre on Climate Change Mitigation in Energy-Intensive Industries (KEI)you have already gained extensive experience with topics such as CO2 capture and process heat. Your work on decarbonisation and energy efficiency in industry provides valuable impetus for companies, politics and science. The recently published study on the ‘Flexibilisation of electrified industrial processes’ is a highly topical issue that the German Federal Ministry for Economic Affairs and Climate Action (BMWK) and the Federal Network Agency also focused on this summer. The potential of flexibility in industry is being discussed intensively with ongoing consultations. So, let's get straight to the heart of the study:
What is the main objective of the study on the flexibilisation of electrified industrial processes, and what challenges are to be addressed?
The main aim of the study is to provide industrial companies and political players with scientifically sound but practice-oriented guidance. Not least in order to ensure greater flexibility in industrial processes and in the nationwide energy system in terms of energy generation, transport and supply. Technical, economic and regulatory challenges are the main focus here. While previous studies have mainly concentrated on making existing production processes more flexible, the main focus of our study is on the future climate-neutral industrial and energy system.
2. What potential for flexibilisation in energy-intensive industrial processes have you identified, and in which areas of industry are these particularly pronounced according to your findings?
In view of the federal climate targets and the current strong expansion of renewable energies, two main technologies can be identified for the future energy supply of energy-intensive industrial processes: a strong electrification of process plants and, where this is not possible, a switch to hydrogen-based processes. Each industrial sector is very individual in terms of technical equipment and requirements. And therefore requires customised solutions.
In the non-ferrous metals sector, for example, electrification has already reached a high level. In the glass industry (flat glass), there is also considerable potential for all-electric furnaces, which is also reflected in the number of KEI funding projects. According to the current state of the art, the mineral industries, such as lime and cement, have less potential for electrification and must reduce fuel-related emissions and replace them with climate-neutral fuels. Steel companies will be heavily reliant on hydrogen technologies for DRI plants. Consequently, no single industry can be explicitly emphasised, as they are all characterised by very individual approaches.
3. Which methodological approaches and models did you use to analyse the flexibilisation options in different industries?
A highly qualified research team, represented by the Fraunhofer ISI and the IOB of RWTH Aachen University, worked on the study. The ENERTILE energy model and the FORECAST industry model were used in the overall analysis to depict the energy and industrial systems of the future. This is combined with specific case studies of companies from the steel, aluminium, glass, cement and chemical industries that demonstrate a successful transition to CO2-free production - for example with regard to electrification, load shifting or hybrid plant supply.
4. What specific recommendations does the study make for industrial companies and political decision-makers to drive forward the flexibilisation of production processes and remove regulatory barriers?
In principle, possible solutions for greater industrial flexibility are linked to three levers: Technology, economics and regulation. The study shows that industrial companies should already optimise their processes as far as technically possible and adapt to the fluctuating electricity supply. On the one hand, however, further technical solutions are required to ensure more electrification and, accordingly, more electricity supply from renewable plants. To this end, several pilot and R&D plants need to be built and trialled in the near future. On the other hand, the current regulation on electricity grid fees prevents flexible usage behaviour on the part of consumers due to the band load privilege. This can be solved by a grid fee reform with more incentives for flexible operation. Courageous action is needed from all stakeholders in the areas mentioned.
5. Thank you very much for your interesting answers. If you could express one wish for the future development of flexibilisation in industry, what do you think would be the most important step towards making industry more flexible and the energy system more sustainable in the long term?
It is not only energy and industrial systems that need more flexibility. Where companies used to be able to draw up long-term investment plans, today's framework conditions also demand faster decisions in economic planning. In addition to reinvesting in existing plants and making funds available for innovative technologies, this also includes reacting to price fluctuations and additional costs that have a direct impact on competitiveness. That's why I think it's important to support companies with funding programmes and other economic instruments such as climate protection contracts and to encourage them to invest in innovations, work more closely with the scientific community and use pilot plants. This is particularly important to us at the KEI and to me personally.