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@toniseibold toniseibold commented Jun 25, 2025

Closes # (if applicable).
PyPSA/pypsa-de#8

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Changes proposed in this Pull Request

This PR endogenizes the production of steel and cement and for brownfield optimizations adds the existing plants for steel, cement, ammonia and methanol.
This PR uses the dataset provided by Neuwirth et al. to add existing industry sites.
Where necessary this dataset is complemented with other datasets since it's limited to EU27 countries only.

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Ammonia

As soon as the config setting config["sector"]["ammonia"] is either True or regional and the optimization runs with perfect or myopic foresight, ammonia plant capacities are added in add_existing_baseyear.

Switching existing Haber-Bosch capacities from natural gas to hydrogen is not permitted since it's associated with retrofitting costs and there are only few Examples.
Comparison of eurostat demand vs. database installed capacity shows a high degree of agreement.

Methanol

Existing methanol capacities are added as grey methanol plants using natural gas as input.
This option is also added in prepare_sector_network to allow a grey route for methanol production.

Steel

There are three routes for steel making implemented. The BF-BOF uses coal to reduce iron ore and produce steel in one process. On the other hand, natural gas and hydrogen direct reduced iron processes reduce iron to hot briquetted iron (HBI). The last step is to produce iron via an electric arc furnace (EAF).
EAF are also necessary to recycle secondary steel however this is still hidden in the electricity for industry load.

Cement

Cement production consists of two processes, clinker production and cement production.
For clinker production, the raw material is fed into a cement kiln, and under high temperature heat the clinker is burnt.
We assume that all high temperature heat is provided via natural gas for now - additional to those specific emissions, there is carbon from the raw material oxidizing which contributes to the specific emissions.
The clinker is then ground with gypsum to get cement.

In general, the production capacities mostly agree with the demand from the JRC-IDEES database. The methanol capacities do not match the naphtha for industry demand since that one is met via oil based routes currently.
In bus regions where the demand is higher than the brownfield capacities, new plants can be built from links added in prepare_sector_network.

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Open ToDos

  • code testing
  • provide data of zenodo
  • add sources to data_retrieval.rst
  • add grey methanol technology parameters to technology-data
    Adding Grey Methanolisation technology-data#248
  • add colors to plotting.default.yaml that actually make sense

Checklist

  • I tested my contribution locally and it works as intended.
  • Code and workflow changes are sufficiently documented.
  • Changed dependencies are added to envs/environment.yaml.
  • Changes in configuration options are added in config/config.default.yaml.
  • Changes in configuration options are documented in doc/configtables/*.csv.
  • Sources of newly added data are documented in doc/data_sources.rst.
  • A release note doc/release_notes.rst is added.

@toniseibold toniseibold changed the title Add industry sites Endogenize steel and cement production and add existing industry sites Oct 21, 2025
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2 participants