Towards fossil-free energy supply: Cost-effective decarbonization measures in pharmaceutical energy systems

The pharmaceutical industry's energy profile, characterized by significant heating and cooling demands and stringent quality standards, presents unique challenges and opportunities for decarbonization. While existing studies primarily focus on renewable energy integration, energy efficiency measures, and Scope 1 and 2 emissions reductions, comprehensive analyses addressing the interplay between energy demand and supply remain scarce. This study adopts a holistic approach to decarbonization, incorporating both demand-side and supplyside measures to maximize energy efficiency and reduce carbon emissions in pharmaceutical production processes. Through expert interviews, data analysis, and thermal energy system modeling of four pharmaceutical production sites, key decarbonization measures were identified and evaluated using a Mixed-Integer Linear Programming (MILP) optimization framework. The results demonstrate that decarbonization rates exceeding 50%, and even 100% in some cases, can be achieved without increasing total annual costs. The transition to electricity-based energy systems, particularly those utilizing heat pumps and heat recovery technologies, was identified as an energy-efficient pathway, significantly lowering primary energy consumption. Where available, integration of biomass and biogas or biomethane showed to yield cost benefits compared to full electrification while also reducing system complexity. This study advances the understanding of decarbonization in the pharmaceutical sector by presenting a costeffective and scalable roadmap that balances technical feasibility, regulatory constraints, and sustainability goals. The findings underscore the importance of integrating tailored demand-side improvements, such as HVAC optimization, with advanced supply-side technologies to achieve substantial emission reductions while maintaining operational efficiency and cost-effectiveness.