Horizon Scan: Deep Decarbonisation Technologies in Industrial Manufacturing

Nishantraj Pandey
Sep 24
2 min read

Industrial manufacturing contributes significantly to global CO₂ emissions. Achieving net zero by 2050 will require transformative technologies in how we produce materials, generate heat, and manage emissions.

This horizon scan provides a three-horizon view of technologies already in use, those emerging in pilots, and those still in research. It highlights examples of electrification, alternative fuels and feedstocks, carbon capture, and material efficiency.

Scientific Horizon (10–20 years)

Artificial Photosynthesis for Solar Fuels: US researchers have created lab-scale “artificial leaf” devices that convert CO₂, water, and sunlight into energy-rich chemicals. If scaled, this technology could transform captured emissions into fuels and feedstocks, closing the carbon loop.

High-Temperature Metal–Organic Frameworks (MOFs): A breakthrough sorbent material can capture CO₂ directly from exhaust streams at 300 °C, suitable for cement kilns and steel plants. Unlike traditional systems, this avoids costly gas cooling and could expand carbon capture in heavy industry.

Graphene-Enhanced Concrete: Adding tiny amounts of graphene to new cement blends increases strength by up to 30%. Stronger concrete means less cement is needed, cutting emissions by 10–30% in construction projects.

Engineering Horizon (5–10 years)

Hydrogen Direct Reduction of Iron (HYBRIT, Sweden)The HYBRIT pilot plant has demonstrated sponge iron production using hydrogen instead of coal, with Volvo already receiving fossil-free steel. Full commercialisation is planned by 2026, potentially cutting steel sector emissions by more than 90%.

Inert Anodes for Aluminium (ELYSIS, Canada): Replacing carbon anodes with inert anodes in aluminium smelting eliminates CO₂ emissions from the process, releasing oxygen instead. Demo plants are operating now, with a commercial rollout expected in the late 2020s.

Electrified Steam Crackers (Germany/Netherlands)BASF, SABIC, and partners have piloted electric furnaces for petrochemical cracking, replacing fossil fuel heat with renewable electricity. This could cut CO₂ from plastic and chemical production by up to 90%.

Business Horizon (0–5 years)

CO₂-Cured Concrete (CarbonCure): Commercial systems inject captured CO₂ into concrete mixes, permanently storing carbon while improving strength. Used at scale, this has already reduced emissions across millions of concrete truckloads globally.

Bio-Based Plastics (Braskem, Brazil): Plastics made from sugarcane-derived ethanol are chemically identical to conventional plastics but have a much lower footprint. Braskem’s facility reports a net negative carbon balance, removing ~3.1 tonnes of CO₂ per tonne of polyethene produced.

Electric Arc Furnace (EAF) Steel Recycling: Recycling scrap steel in EAFs reduces emissions by around 75% compared to coal-fired blast furnaces. Already mainstream in the US and EU, the impact grows as electricity grids decarbonise.

Why This Matters

These nine technologies show a roadmap for deep decarbonisation in manufacturing.

Commercial solutions like CO₂-cured concrete and EAFs can cut emissions today.
Engineering pilots such as hydrogen steel and inert anodes will scale through the 2030s.
Scientific innovations like artificial photosynthesis and neuromorphic computing may define the longer term.

Progress will depend on adopting the tools available now while investing in tomorrow's breakthroughs.