BASF is investing in one of the most powerful heat pump systems at its main facility in Ludwigshafen. The aim is to use waste heat from one of the largest production plants at the chemical site – Steamcracker II - as a thermal energy source for generating CO2-free steam. The use of this emission-free steam in formic acid production has the potential to reduce the greenhouse gas emitted by the process by 98 % in future.
Piller supplies the heart of the system
The components from Piller Blowers & Compressors sit at the heart of one of the world's most powerful heat pump systems. The machines in the VapoLine range from Piller efficiently compress vaporous waste heat from industrial processes, thereby bringing it to a usable temperature level – the basis for the heat pump function. Piller supplies six VapoFlex machines (line 1) and five further VapoFlex machines (line 2) – for steam generation. The system comprises a total of 11 compressor stages, including the electrical drive systems and the corresponding accessory components. Delivery is scheduled for mid-2026. The system requires maximum compressor capacity and will compress around 500,000 tons of steam per year. Beside the machines with impeller diameters of up to 2.25m, the system is equipped with a modern operating point monitoring system. The operator is informed when limits are reached or exceeded here, so that maximum machine availability can be secured.
The project is being realised at BASF together with plant manufacturer GIG Karasek. The CompriVAP system from GIG Karasek combines a plate falling film evaporator, flash tank, and the Piller compressor cascade, in order to create a pioneering overall technological concept. Thanks to its hybrid design, it produces completely oxygen-free steam and uses pure water as a safe and environmentally friendly working medium. The flexible operation with infinitely variable partial load capacity and electricity price-optimized start-stop cycles enables economical operation, while intelligent condition monitoring increases availability and reduces maintenance costs.
Piller in the process
The innovative steam compression system sets new standards in terms of both the efficiency and quality of steam generation. In a first step, waste heat is used in a flash cycle of GIG Karasek to generate flash steam under vacuum conditions. This steam is then compressed to a pressure above atmospheric pressure by six VapoFlex arranged in series (line 1). A key requirement for the downstream process is to avoid ingress of even minimal quantities of atmospheric oxygen. For design reasons, meeting this strict process requirement is a complex undertaking for the system comprising compressors and connecting pipelines in the vacuum area. A concept with an intermediate heat exchanger in the form of a customised plate falling film evaporator from GIG Karasek was therefore selected. This prevents atmospheric air from entering the downstream process. The newly acquired live steam in the intermediate heat exchanger, which is at above atmospheric conditions, is then compressed to the required pressure and temperature level by five further VapoFlex units arranged in series (line 2). The result: up to 60 tons of steam per hour.
Milestone for the green transformation
While the green transformation is becoming increasingly important across all industries, it is a clearly defined strategic focus for BASF. One key to this is the use of industrial waste heat. The compressor technology of the VapoLine efficiently raises waste heat vapor to a higher temperature level. The energy can then, for example, be used directly in production, which increases efficiency and reduces CO2 emissions – thereby boosting both competitiveness and sustainability. This project is a milestone, as Andreas Schnitzhofer, Managing Director at GIG Karasek, is keen to stress: "This is a game changer for us. Today, waste heat often remains unused or is cooled down at great expense. However, it is actually a valuable resource and a genuine alternative to fossil fuels. Our solution uses this energy source efficiently. The investment is typically amortised after two to three years."
BASF is set to reduce CO2 emissions by up to 100,000 tons per year thanks to this project. This is an important step on the road to net zero CO2 emissions by 2050. Thanks to the scalability and adaptability of the overall system, numerous applications with various waste heat sources are possible. The BASF project shows the great potential of industrial waste heat utilisation and can inspire other industries to implement similar solutions for CO2 reduction.
Info box:
o The COP is approximately 3 for the entire system
o Inlet temperature 57 °C (saturated)
o Outlet temperature 158 °C (saturated) / 190 °C (superheated)
o Temperature increase of 101 K (saturated) / 133 K (superheated)
o Piller machines: 11x VapoFlex
o EPC contractor for the overall project: GIG Karasek
o Overall system: CompriVAP from GIG Karasek
