Techno-economic analysis and comparison of coal-based chemical technologies with consideration of water resources scarcity

Existing techno-economic analyses of modern coal chemical technologies (MCCTs) neglect water constraints, which may underestimate the production cost of MCCTs and thus mislead investment activities. Considering this background, this study incorporated water scarcity and indirect water cost into a classic techno-economic evaluation model of MCCT. Using this model, our work evaluated and compared the techno-economic indicators with the latest data for four typical MCCTs, including coal-to-liquids (CTL), synthetic natural gas (SNG), coal-to-olefin (CTO), and coal-to-ethylene glycol (CTEG). The results demonstrate the following: 1) The production costs of CTL, SNG, CTO, and CTEG are 5185 CNY/t, 2653 CNY/kNm3, 5918 CNY/t, 4055 CNY/t, respectively. Under the current prices of oil-related products, investment in SNG and CTEG would be risky, investment in CTL should be considered cautiously, and investment in CTO could lead to a profit. 2) Under the current market price of water resources, which does not consider the water constraint of MCCTs, the production cost would be underestimated by at most 12.4% for CTL, 10.6% for SNG, 27.5% for CTO, and 32.4% for CTEG. The sensitivity of the results to some key parameters and investment recommendations considering profitability, capital investment, material consumption, water constraints, and CO2 emissions are also discussed and provided

A review on the valorization of CO2. Focusing on the thermodynamics and catalyst design studies of the direct synthesis of dimethyl ether

The direct synthesis of dimethyl ether (DME) on bifunctional catalysts is highly attractive for valorizing CO2 and syngas derived from biomass gasification and is a key process to reduce greenhouse gas emissions. DME economy (conventionally based on its use as fuel) arouses growing interest, in parallel with the development of different routes for its conversion into hydrocarbons (fuels and chemicals) and H-2 production. This review, after analyzing different routes and catalytic processes for the valorization of CO2, focuses on studies regarding the thermodynamics of the direct synthesis of DME and the advances in the development of new catalysts. Compared to the synthesis of methanol and the synthesis of DME in two stages, carrying out the reactions of methanol synthesis and its dehydration to DME in the same reactor favors the formation of DME from CO2 and from CO2 co-fed with syngas. Starting from the experience for syngas feedstocks, numerous catalysts have been studied. The first catalysts were physical mixtures or composites prepared by extrusion of methanol synthesis catalysts (CuO-ZnO with different carriers and promoters) and dehydration catalysts (mainly gamma-Al2O3 and HZSM-5 zeolite). The performance of the catalysts has been progressively improved with different modifications of the composition and properties of the components to upturn the activity (lower for the hydrogenation of CO2 than for CO) and selectivity, and to minimize the deactivation by coke and by sintering of the metallic function. The core-shell configuration of the bifunctional catalyst allows physically separating the environments of the reactions of methanol synthesis and its conversion into DME. The confinement facilitates the extent of both reactions and improves the stability of the catalyst, since the synergies of the deactivation mechanisms are eliminated.This work has been carried out with the financial support of the Ministry of Science, Innovation and Universities of the Spanish Government (PID2019-108448RB-100); the Basque Government (Project IT1645-22); the European Regional Development Funds (ERDF); and the European Commission (HORIZON H2020-MSCA RISE-2018. Contract No. 823745)

Exergetic, economic and carbon emission studies of bio-olefin production via indirect steam gasification process

The indirect steam gasification of biomass to olefins (IDBTO) coupled with CO2 utilization was proposed and simulated. Energy and exergy efficiencies, net CO2 emissions, and economic evaluation were performed against IDBTO as well as the direct oxygen-steam gasification of biomass to olifins (DBTO). The influences of unreacted gas recycling fraction (RU) and CO2 to dry biomass mass ratio (CO2/B) on the thermodynamic performance of the processes were also studied. The results showed that the yields of olefins of DBTO and IDBTO were 17 wt% and 19 wt%, respectively, the overall energy and exergy efficiencies of the IDBTO were around 49% and 44%, which were 8% and 7% higher than those of the DBTO process, respectively. A higher RU was found favor higher energy and exergy efficiencies for both routes. Besides, for the IDBTO process, it is found that the addition of CO2 to gasification system led to an improvement in both energy efficiency and exergy efficiency by around 1.6%. Moreover, life-cycle net CO2 emission was predicted to be -4.4 kg CO2 eq./ kg olefins for IDBTO, while for DBTO, it was -8.7 kg CO2 eq./ kg. However, the quantitative economic performance of IDBTO was superior to that of the DBTO process

Production costs from energy intensive industries in the EU and third countries

This report compares estimated production costs from four energy-intensive industries (steel, cement, chemical and non-ferrous metals) in the European Union and some third countries. Production costs have been estimated following a bottom-up approach, i.e. using information at facility level from a representative number of facilities. Costs are broken down to key factors, such as material, labour and energy costs and exclude capital costs (depreciation and interest). Moreover, the energy costs are estimated considering the effect of the state of technologies and the fuel mix in each country. For the iron and steel industry the production costs of hot-rolled coil and wire rod are analysed as representative flat and long products, respectively. The production costs of these products have been estimated for both the integrated route (blast furnace-basic oxygen furnace) and the recycling route (electrical arc furnace). For the chemical industry, the products analysed are ammonia, methanol, ethylene and propylene; whereas for the non-ferrous metals the analysis is focused on primary aluminium production, copper cathodes and slabs of zinc. Most of the EU28 production costs are ranked (when compared with certain competitor countries) between the 75th percentile and the maximum production cost. These costs are highest in the EU relative to other countries or regions in the case of flat products from the recycling route, ammonia and methanol. For long products -from the recycling route-, flat products -from the integrated route-, ethylene, propylene -refinery grade- and copper anode the EU28 production costs are between the median (the median separates the higher half of the costs from the lower half) and the 75th percentile of all production costs estimated. In the case of cement, the EU28 production cost is quite similar to the value of the median cost. There are also cases in which the EU28 production costs were among the lowest costs, namely for copper cathode and zinc slabs. It is worth noting that the contribution of energy costs to production costs is the highest in the EU only for methanol and ammonia. For all other products and industries analysed (including methanol and ammonia), other components of the cost (raw materials, labour and others or feedstock) contribute more to final costs than energy (natural gas is considered as a feedstock for methanol and ammonia). It is also noteworthy that, in most industries and products, the behaviour of credits (by-products, home scrap, electricity production from waste gases or from combined heat and power) contributes to reduce production costs more in the EU than it does in other countries or regions.JRC.F.6-Energy Technology Policy Outloo

HZSM-5/SAPO-34 based catalysts for the transformation of dimethyl ether into olefins

[EN] The catalytic transformation of dimethyl ether with HZSM-5/SAPO-34 based catalysts has been studied. The process aims to selectively produce light olefins and propylene in particular, attending to their higher market demand, while using a fixed bed reactor and a microporous acid HZSM-5 zeolite, SAPO-34 catalyst and a composite catalyst obtained by physical blending of the previous acid phases. This Bachelor Thesis focuses on exploring the effect of process conditions (including the catalyst) on the reaction indexes (conversion, yield and selectivity). Besides, it will open new research frontiers for the student in terms of catalyst synthesis and characterization, laboratory methods and spectroscopy, among others

Integral techno-economic comparison and greenhouse gas balances of different production routes of aromatics from biomass with CO₂ capture

The techno-economic performance and CO2 equivalent (CO2eq) reduction potential of bio-based aromatic production cases with and without CO2 capture and storage (CCS) have been evaluated and compared to those of fossil-based aromatic production. The bio-cases include tail gas reactive pyrolysis (TGRP), catalytic pyrolysis (CP), hydrothermal liquefaction (HTL), gasification-methanol-aromatics (GMA), and Diels-Alder of furan/furfural combined with catalytic pyrolysis of lignin (FFCA). The crude oil-based naphtha catalytic reforming (NACR) routes have GHG emissions of 43.4 and 43.9 t CO2eq/t aromatics with and without CCS (NACR-CCS), respectively. Except for HTL, all the biomass cases with CCS show negative emissions between −6.1 and −1.1 t CO2eq/t aromatics with avoidance costs ranging from 27.7 to 93.3 $/t CO2eq. Under favorable conditions, GMA with CCS (GMA-CCS) has the lowest emissions (−14.6 t CO2eq/t aromatics), while CP with CCS (CP-CCS) shows the lowest avoidance cost (12.3$/t CO2eq). All biomass based aromatics production techniques are currently at the laboratory or demonstration stages, except for CP, which has pilot plants. The results indicate that bio-based aromatics production, with their reasonable avoidance costs and low, or potentially negative, greenhouse gas (GHG) emissions, are an attractive option to compensate for the expected aromatic production shortages in the coming decades

Energy efficiency and GHG emissions: Prospective scenarios for the Chemical and Petrochemical Industry

This study analyses the savings potential of energy consumption and GHG emissions from cost-effective technological improvements in the chemical and petrochemical industry up to 2050. The analysis follows a bottom-up approach; that is, it is based on information at facility level of existing plants with their production characteristics, best available and innovative technologies. The analysis includes 26 basic chemical compounds that cover 75 % of the total energy use (including energy used as feedstock) and more than 90 % of GHG emissions of the chemical sector in 2013. The bottom-up approach includes an annual cost-effectiveness analysis of the uptake of best available and innovative technologies in each facility up to 2050. The projections and assumptions used are in accordance with the reference scenario of the European Commission. In absolute terms, from 2013-2050 the total energy consumption increases by 39.2 % and the GHG emissions' decrease by 14.7 %; these values include the effect (and depend on) a demand increase by 45.6 %. In 2050, without any technological improvement, the GHG emissions and energy consumption would be 36 % and 4 % higher. The minor effect of technological improvements on energy savings can be partly explained by the fact that 73.5 % of the total energy consumed in the manufacturing of the products covered in this study is incorporated in the final products, and most of new technologies have an impact on the direct energy use, but not on the non-energy use.JRC.C.7-Knowledge for the Energy Unio

Generation of synthesis gas for fuels and chemicals production

Many scientists believe that the oil production will peak in the near future, if the peak has not already occurred. Peak oil theories and uncertain future oil deliveries have stimulated interest in alternative sources of fuel and chemicals. This interest has been enhanced by concerns about energy security and about the climate change caused by emissions of carbon dioxide. The result has been increased interest in substituting fossil fuels with renewable energy sources such as wind, solar and biomass. However, this has proved particularly difficult in the transportation sector. The most likely source of renewable hydrocarbon fuels for transportation is biomass. It comes in many forms, none of which are suitable for direct use in internal combustion engines and gas turbines. Thus the biomass has to be refined to convert its energy into a more usable form. The most versatile conversion of biomass is thermochemical conversion via gasification and downstream synthesis, which allows the production of both fuels and chemicals. In the biomass gasification process, a gasifier converts the solid biomass into a gaseous product known as producer gas. The producer gas contains the desired components carbon monoxide and hydrogen, but it also contains water, carbon dioxide, lower hydrocarbons, tars and impurities that need to be removed from the gas. Reforming the tars and hydrocarbons in producer gas is difficult because of the amount of sulphur present. This thesis investigates the use of reverse-flow reactors to reform the tars and hydrocarbons in biomass generated producer gas.. Reverse-flow reactors operate by periodically reversing the direction of flow to enable high levels of heat recovery. The high heat recovery enables non-catalytic reformers to be operated at efficiencies near that of catalytic reformers. The operation of reverse-flow reactors is investigated experimentally in a tar-cracking reactor using dolomite as bed material and also theoretically using computer models. The investigations show that reverse-flow reactors have great potential, offering a chemically robust alternative to conventional reformers when operating on sulphur-containing biomass-generated producer gas. Furthermore, operation of reverse-flow tar crackers using dolomite as bed material is an efficient and viable solution for tar removal and syngas boosting. The producer gas also contains ammonia in varying amounts depending on the gasifier’s operating parameters and feedstock. Ammonia can be a poison for catalysts and, if the producer gas is burnt, will produce elevated levels of NOX in the flue gas. The selective catalytic oxidation of ammonia in synthesis gas was thus also investigated by experiments on a model synthesis gas. This thesis also covers mass and energy balance calculations to determine the efficiency and economics of synthetic fuels and chemicals plants. Several possible plant configurations were investigated, both stand-alone and integrated. The integration of a pulp and paper mill with a fuel synthesis plant is a very likely scenario as the biomass logistics are already located on-site. Another possible integration scenario involves steel plants, where large quantities of energy-rich gases are handled as off-gases in coke production. Utilisation of this off-gas coupled with biomass gasification was also investigated. In the stand-alone plants, the difference between reverse-flow reformers and conventional non-catalytic reformers was investigated as front-ends to well-head gas upgrading to produce crude oil via the Fischer-Tropsch synthesis. Furthermore a well-to-wheel comparison of synthetic natural gas, methanol, ethanol, dimethyl ether, Fischer-Tropsch diesel and synthetic gasoline was performed. The comparison used woody biomass as feedstock and computed mass and energy balances for complete plants from gasifier to fuel as well as for lignocellulosic ethanol production by fermentation. Efficiency in regard to feedstock to travel distance (Well-to-Wheel) and the cost of transportation was also investigated. Ammonia is one of the most valuable chemicals for modern agriculture. Current production is almost entirely based on fossil fuels. Thus small-scale production of ammonia from renewable feedstocks was also investigated

Techno-economic feasibility study of a methanol plant using carbon dioxide and hydrogen

In 2015, more than 80% of energy consumption was based on fossil resources. Growing population especially in developing countries fuel the trend in global energy consumption. This constant increase however leads to climate change caused by anthropogenic greenhouse gas (GHG) emissions. GHG, especially CO2 mitigation is one of the top priority challenges in the EU. Amongst the solutions to mitigate future emissions, carbon capture and utilization (CCU) is gaining interest. CO2 is a valuable, abundant and renewable carbon source that can be converted into fuels and chemicals. Methanol (MeOH) is one of the chemicals that can be produced from CO2. It is considered a basic compound in chemical industry as it can be utilised in a versatility of processes. These arguments make methanol and its production from CO2 a current, intriguing topic in climate change mitigation. In this master’s thesis first the applications, production, global demand and market price of methanol were investigated. In the second part of the thesis, a methanol plant producing chemical grade methanol was simulated in Aspen Plus. The studied plants have three different annual capacities: 10 kt/a, 50 kt/a and 250 kt/a. They were compared with the option of buying the CO2 or capturing it directly from flue gases through a carbon capture (CC) unit attached to the methanol plant. The kinetic model considering both CO and CO2 as sources of carbon for methanol formation was described thoroughly, and the main considerations and parameters were introduced for the simulation. The simulation successfully achieved chemical grade methanol production, with a high overall CO2 conversion rate and close to stoichiometric raw material utilization. Heat exchanger network was optimized in Aspen Energy Analyzer which achieved a total of 75% heat duty saving. The estimated levelised cost of methanol (LCOMeOH) ranges between 1130 and 630 €/t which is significantly higher than the current listed market price for fossil methanol at 419 €/t. This high LCOMeOH is mostly due to the high production cost of hydrogen, which corresponds to 72% of LCOMeOH. It was revealed that selling the oxygen by-product from water electrolysis had the most significant effect, reducing the LCOMeOH to 475 €/t. Cost of electricity also has a significant influence on the LCOMeOH, and for a 10 €/MWh change the LCOMeOH changed by 110 €/t. Finally, the estimated LCOMeOH was least sensitive for the change in cost of CO2. When comparing owning a CC plant with purchasing CO2, it was revealed that purchasing option is only beneficial for smaller plants