Aiming for CO2-neutral solvents for surface cleaning

On the way to CO2-neutral solvents for surface cleaning: A solvent specialist saves around 25 percent energy by converting its own rotary kiln and implementing a "waste to energy" concept.

CO2-neutral solvents are the goal of Richard Geiss GmbH. The company from Offingen (Bavaria), which produces solvents for industrial surface cleaning, has come a big step closer to achieving this goal thanks to the conversion of its in-house rotary kiln. In the rotary kiln, distillation residues from the solvent treatment process are thermally recycled on site. Richard Geiss GmbH uses the resulting energy for solvent processing and reduces its gas consumption by around a quarter with the "Waste to Energy" concept. This also reduces the CO2 footprint by 1,482 tons per year. The family-run company recently invested 2.1 million euros in the complete conversion of the rotary kiln.

"We have successfully completed our mammoth 'furnace modernization' project and thus set a milestone on our path to CO2-neutral solvents. After all, CO2-reduced production not only has a positive effect on our company's CO2 footprint, but ultimately also on the CO2 balance of our products. Of course, this is also interesting for our customers and their environmental management," explains Bastian Geiss, Managing Partner of Richard Geiss GmbH.

The solvent specialist from Offingen has been operating a circular economy for decades and is one of Europe's leading experts in solvent recycling. Some of the distillates save up to 90 percent CO2 compared to fresh products.

Richard Geiss GmbH can process up to 50,000 tons of waste material per year into high-purity distillates at its site in Offingen. "Thanks to the modernized rotary kiln, we now generate around a quarter of the energy for the distillation process ourselves at our site, thereby saving gas and reducing the carbon footprint of our solvent recyclates enormously," explains Bastian Geiss. The modernization of the rotary kiln has also significantly expanded the range of materials that can be recycled there. This has also doubled the incineration capacity: from 3,000 tons to 6,000 tons per year.

Another advantage: the fact that the solvent specialist can independently thermally recycle the residues from the distillation process directly on site has not only deepened the concept of the circular economy, but also saves on logistics and transport routes. Thanks to the modernized rotary kiln, the family-run company estimates that there will be a good 300 fewer truck loads per year that were previously sent for external disposal. This is also a plus for the environment and saves CO2.

Richard Geiss GmbH produces not only heating energy, but also 65% of the electricity it needs itself, in the form of hydroelectric and solar energy. The solvent specialist consumes around three million kilowatt hours of electricity a year, as much as almost 750 four-person households. Around two thirds of this comes from a hydroelectric power plant and a photovoltaic system at the Offingen site. "We have been pursuing a self-sufficient energy supply for years. It is particularly important to us that the electricity we produce ourselves comes from renewable energy sources," emphasizes Bastian Geiss.

The majority of the electricity produced is supplied by a hydroelectric power plant at the site, which the solvent specialist has been operating for decades. Around two thirds of the electricity from this flows into Richard Geiss GmbH's production every year. Since 2014, a solar power plant has been supplementing electricity generation at the site. More than 260,000 kWh per year come from the PV system, which also feeds 100 percent directly into the company.

Richard Geiss GmbH also takes an environmentally friendly approach to the transportation of solvents and the mobility of its employees. The solvents are increasingly being transported by rail for distribution. In 2023, 170 tons of CO2 were saved thanks to rail transport. With the company's own state-of-the-art fleet, the recycling company not only offers a complete all-round service for customers, but also maximum safety when transporting the solvents.

There are also e-charging stations in the parking lot in Offingen. They are available for employees to "fill up" their electric vehicles. The company has already converted 13 company cars to hybrid. Also cool and green: Richard Geiss GmbH offers its employees bike leasing for an environmentally friendly and healthy commute.

"Everyone wants a climate-neutral industry: the German government by 2045, the EU by 2050. The chemical industry in particular is facing major upheavals and has to make various adjustments to achieve this goal," explains Bastian Geiss. "On the one hand, we are therefore continuing to focus consistently on the circular economy and the processing of solvents in order to conserve resources. On the other hand, we produce most of the energy we need ourselves and want to expand this even further in the future," says Bastian Geiss, giving an outlook.

A 2019 study by the German Chemical Industry Association (VCI) showed that greenhouse gas-neutral chemistry in Germany is technologically possible; the key to zero CO2 lies primarily in the type of energy supply. Currently, this still comes largely from fossil fuels. "We are showing how things can be done differently: with a circular economy and self-produced energy," emphasizes Bastian Geiss. (OM-5/24)