Methanol Synthesis from Steel Mill Exhaust Gases: Challenges for the Industrial Cu/ZnO/Al2O3Catalyst

Investigating technology development in the energy sector and its implications for Indonesia

Innovations for a low-carbon economy and carbon neutrality are the focal points of technology development in the energy sector. This paper aims to investigate the progress of technology and advancements in the energy sector and the implications for Indonesia via two routes, viz., renewable energy and energy efficiency. The methodology employed in this research is divided into two parts. Firstly, an extensive literature review was conducted to identify prevalent research trends within the energy sector. Second, a case study method was performed to gain a comprehensive understanding of energy transformation within the electricity and steel sectors. The study presents two key findings. First, the energy sector has experienced significant technological disruption, providing the opportunity for Indonesia to transition towards a low-carbon development. This includes smart grids, energy-intensive industries, electric vehicles, and storage (pumped storage and battery). Second, lessons from the steel industry show that the technology selection is sensitive to parent company, and this is not easily captured in literature studies. Indonesian has gained many benefits from the global technological disruption, but this is not sufficient without developing changes in support system and consumer behavior.

Catalytic dechlorination of 1,2-DCA in nano Cu0-borohydride system: effects of Cu0/Cun+ ratio, surface poisoning, and regeneration of Cu0 sites

Aqueous-phase catalyzed reduction of organic contaminants via zerovalent copper nanoparticles (nCu⁰), coupled with borohydride (hydrogen donor), has shown promising results. So far, the research on nCu⁰ as a remedial treatment has focused mainly on contaminant removal efficiencies and degradation mechanisms. Our study has examined the effects of Cu⁰/Cuⁿ⁺ ratio, surface poisoning (presence of chloride, sulfides, humic acid (HA)), and regeneration of Cu⁰ sites on catalytic dechlorination of aqueous-phase 1,2-dichloroethane (1,2-DCA) via nCu⁰-borohydride. Scanning electron microscopy confirmed the nano size and quasi-spherical shape of nCu⁰ particles. X-ray diffraction confirmed the presence of Cu⁰ and Cu₂O and x-ray photoelectron spectroscopy also provided the Cu⁰/Cuⁿ⁺ ratios. Reactivity experiments showed that nCu⁰ was incapable of utilizing H₂ from borohydride left over during nCu⁰ synthesis and, hence, additional borohydride was essential for 1,2-DCA dechlorination. Washing the nCu⁰ particles improved their Cu⁰/Cuⁿ⁺ ratio (1.27) and 92% 1,2-DCA was removed in 7 h with k_obs = 0.345 h^-1 as compared to only 44% by unwashed nCu⁰ (0.158 h^-1) with Cu⁰/Cuⁿ⁺ ratio of 0.59, in the presence of borohydride. The presence of chloride (1000-2000 mg L^-1), sulfides (0.4-4 mg L^-1), and HA (10-30 mg L^-1) suppressed 1,2-DCA dechlorination; which was improved by additional borohydride probably via regeneration of Cu⁰ sites. Coating the particles decreased their catalytic dechlorination efficiency. 85-90% of the removed 1,2-DCA was recovered as chloride. Chloroethane and ethane were main dechlorination products indicating hydrogenolysis as the major pathway. Our results imply that synthesis parameters and groundwater solutes control nCu⁰ catalytic activity by altering its physico-chemical properties. Thus, these factors should be considered to develop an efficient remedial design for practical applications of nCu⁰-borohydride.

Economic Evaluation of Renewable Hydrogen Integration into Steelworks for the Production of Methanol and Methane

This work investigates the cost-efficient integration of renewable hydrogen into steelworks for the production of methane and methanol as an efficient way to decarbonize the steel industry. Three case studies that utilize a mixture of steelworks off-gases (blast furnace gas, coke oven gas, and basic oxygen furnace gas), which differ on the amount of used off-gases as well as on the end product (methane and/or methanol), are analyzed and evaluated in terms of their economic performance. The most influential cost factors are identified and sensitivity analyses are conducted for different operating and economic parameters. Renewable hydrogen produced by PEM electrolysis is the most expensive component in this scheme and responsible for over 80% of the total costs. Progress in the hydrogen economy (lower electrolyzer capital costs, improved electrolyzer efficiency, and lower electricity prices) is necessary to establish this technology in the future.

The potential of NO+ and O2 +• in switchable reagent ion proton transfer reaction time-of-flight mass spectrometry

Selected ion flow tube mass spectrometry (SIFT-MS) and proton transfer reaction mass spectrometry with switchable reagent ion capability (PTR+SRI-MS) are analytical techniques for real-time qualification and quantification of compounds in gas samples with trace level concentrations. In the detection process, neutral compounds-mainly volatile organic compounds-are ionized via chemical ionization with ionic reagents or primary ions. The most common reagent ions are H₃ O⁺ , NO⁺ and O₂ ^+• . While ionization with H₃ O⁺ occurs by means of proton transfer, the ionization via NO⁺ and O₂ ^+• offers a larger variety on ionization pathways, as charge transfer, hydride abstraction and so on are possible. The distribution of the reactant into various reaction channels depends not only on the usage of either NO⁺ or O₂ ^+• , but also on the class of analyte compounds. Furthermore, the choice of the reaction conditions as well as the choice of either SIFT-MS or PTR+SRI-MS might have a large impact on the resulting products. Therefore, an overview of both NO⁺ and O₂ ^+• as reagent ions is given, showing differences between SIFT-MS and PTR+SRI-MS as used analytical methods revealing the potential how the knowledge obtained with H₃ O⁺ for different classes of compounds can be extended with the usage of NO⁺ and O₂ ^+• .

Single-Atom (Iron-Based) Catalysts: Synthesis and Applications

Supported single-metal atom catalysts (SACs) are constituted of isolated active metal centers, which are heterogenized on inert supports such as graphene, porous carbon, and metal oxides. Their thermal stability, electronic properties, and catalytic activities can be controlled via interactions between the single-metal atom center and neighboring heteroatoms such as nitrogen, oxygen, and sulfur. Due to the atomic dispersion of the active catalytic centers, the amount of metal required for catalysis can be decreased, thus offering new possibilities to control the selectivity of a given transformation as well as to improve catalyst turnover frequencies and turnover numbers. This review aims to comprehensively summarize the synthesis of Fe-SACs with a focus on anchoring single atoms (SA) on carbon/graphene supports. The characterization of these advanced materials using various spectroscopic techniques and their applications in diverse research areas are described. When applicable, mechanistic investigations conducted to understand the specific behavior of Fe-SACs-based catalysts are highlighted, including the use of theoretical models.

Integration of Renewable Hydrogen Production in Steelworks Off-Gases for the Synthesis of Methanol and Methane

The steel industry is among the highest carbon-emitting industrial sectors. Since the steel production process is already exhaustively optimized, alternative routes are sought in order to increase carbon efficiency and reduce these emissions. During steel production, three main carbon-containing off-gases are generated: blast furnace gas, coke oven gas and basic oxygen furnace gas. In the present work, the addition of renewable hydrogen by electrolysis to those steelworks off-gases is studied for the production of methane and methanol. Different case scenarios are investigated using AspenPlusTM flowsheet simulations, which differ on the end-product, the feedstock flowrates and on the production of power. Each case study is evaluated in terms of hydrogen and electrolysis requirements, carbon conversion, hydrogen consumption, and product yields. The findings of this study showed that the electrolysis requirements surpass the energy content of the steelwork’s feedstock. However, for the methanol synthesis cases, substantial improvements can be achieved if recycling a significant amount of the residual hydrogen.

Oxygenated Transport Fuels from Carbon Dioxide : Driving towards Net Zero

The restructuring of the economy post-COVID-19 coupled to the drive towards Net Zero carbon dioxide emissions means we must rethink the way we use transport fuels. Fossil-carbon based fuels are ubiquitous in the transport sector, however there are alternative synthetic fuels that could be used as drop-in or replacement fuels. The main hurdles to achieving a transition to synthetic fuels are the limited availability of low-cost carbon dioxide at an appropriate purity, the availability of renewable hydrogen and, in the case of hydrocarbons, catalysts that are selective for small and particular chain lengths. In this paper we will consider some of the alternative fuels and methods that could reduce cost, both economically and environmentally. We recommend that increased effort in the rapid development of these fuels should be a priority in order to accelerate the possibility of achieving Net Zero without costly infrastructure changes. As ground transportation offers a more straightforward approach legislatively, we will look at oxygenated organic fuels as an alternative drop-in replacement for hydrocarbons.

Application of Liquid Hydrogen Carriers in Hydrogen Steelmaking

Steelmaking is responsible for approximately one third of total industrial carbon dioxide (CO2) emissions. Hydrogen (H2) direct reduction (H-DR) may be a feasible route towards the decarbonization of primary steelmaking if H2 is produced via electrolysis using fossil-free electricity. However, electrolysis is an electricity-intensive process. Therefore, it is preferable that H2 is predominantly produced during times of low electricity prices, which is enabled by the storage of H2. This work compares the integration of H2 storage in four liquid carriers, methanol (MeOH), formic acid (FA), ammonia (NH3) and perhydro-dibenzyltoluene (H18-DBT), in H-DR processes. In contrast to conventional H2 storage methods, these carriers allow for H2 storage in liquid form at moderate overpressures, reducing the storage capacity cost. The main downside to liquid H2 carriers is that thermochemical processes are necessary for both the storage and release processes, often with significant investment and operational costs. The carriers are compared using thermodynamic and economic data to estimate operational and capital costs in the H-DR context considering process integration options. It is concluded that the use of MeOH is promising compared to the other considered carriers. For large storage volumes, MeOH-based H2 storage may also be an attractive option to the underground storage of compressed H2. The other considered liquid H2 carriers suffer from large thermodynamic barriers for hydrogenation (FA) or dehydrogenation (NH3, H18-DBT) and higher investment costs. However, for the use of MeOH in an H-DR process to be practically feasible, questions regarding process flexibility and the optimal sourcing of CO2 and heat must be answered.

A novel approach for kinetic measurements in exothermic fixed bed reactors: advancements in non-isothermal bed conditions demonstrated for methanol synthesis

A novel approach for the investigation of reaction kinetics using a polytropic miniplant reactor featuring a highly resolved fibre optic temperature measurement and FTIR gas phase analysis is presented for methanol synthesis.

Carbon Allocation in Multi-Product Steel Mills That Co‐process Biogenic and Fossil Feedstocks and Adopt Carbon Capture Utilization and Storage Technologies

This work investigates the effects of carbon allocation on the emission intensities of low-carbon products cogenerated in facilities that co‐process biogenic and fossil feedstocks and apply the carbon capture utilization and storage technology. Thus, these plants simultaneously sequester CO2 and synthesize fuels or chemicals. We consider an integrated steel mill that injects biomass into the blast furnace, captures CO2 for storage, and ferments CO into ethanol from the blast furnace gas. We examine two schemes to allocate the CO2 emissions avoided [due to the renewable feedstock share (biomass) and CO2 capture and storage (CCS)] to the products of steel, ethanol, and electricity (generated through the combustion of steel mill waste gases): 1) allocation by (carbon) mass, which represents actual carbon flows, and 2) a free-choice attribution that maximizes the renewable content allocated to electricity and ethanol. With respect to the chosen assumptions on process performance and heat integration, we find that allocation by mass favors steel and is unlikely to yield an ethanol product that fulfills the Renewable Energy Directive (RED) biofuel criterion (65% emission reduction relative to a fossil comparator), even when using renewable electricity and applying CCS to the blast furnace gas prior to CO conversion into ethanol and electricity. In contrast, attribution fulfills the criterion and yields bioethanol for electricity grid intensities <180 gCO2/kWhel without CCS and yields bioethanol for grid intensities up to 800 gCO2/kWhel with CCS. The overall emissions savings are up to 27 and 47% in the near-term and long-term future, respectively. The choice of the allocation scheme greatly affects the emissions intensities of cogenerated products. Thus, the set of valid allocation schemes determines the extent of flexibility that manufacturers have in producing low-carbon products, which is relevant for industries whose product target sectors that value emissions differently. We recommend that policymakers consider the emerging relevance of co‐processing in nonrefining facilities. Provided there is no double-accounting of emissions, policies should contain a reasonable degree of freedom in the allocation of emissions savings to low-carbon products, so as to promote the sale of these savings, thereby making investments in mitigation technologies more attractive to stakeholders.

Renewable Hydrogen Production Processes for the Off-Gas Valorization in Integrated Steelworks through Hydrogen Intensified Methane and Methanol Syntheses

Within integrated steelmaking industries significant research efforts are devoted to the efficient use of resources and the reduction of CO2 emissions. Integrated steelworks consume a considerable quantity of raw materials and produce a high amount of by-products, such as off-gases, currently used for the internal production of heat, steam or electricity. These off-gases can be further valorized as feedstock for methane and methanol syntheses, but their hydrogen content is often inadequate to reach high conversions in synthesis processes. The addition of hydrogen is fundamental and a suitable hydrogen production process must be selected to obtain advantages in process economy and sustainability. This paper presents a comparative analysis of different hydrogen production processes from renewable energy, namely polymer electrolyte membrane electrolysis, solid oxide electrolyze cell electrolysis, and biomass gasification. Aspen Plus® V11-based models were developed, and simulations were conducted for sensitivity analyses to acquire useful information related to the process behavior. Advantages and disadvantages for each considered process were highlighted. In addition, the integration of the analyzed hydrogen production methods with methane and methanol syntheses is analyzed through further Aspen Plus®-based simulations. The pros and cons of the different hydrogen production options coupled with methane and methanol syntheses included in steelmaking industries are analyzed.

Chemical Batteries with CO2

Efforts to obtain raw materials from CO₂ by catalytic reduction as a means of combating greenhouse gas emissions are pushing the boundaries of the chemical industry. The dimensions of modern energy regimes, on the one hand, and the necessary transport and trade of globally produced renewable energy, on the other, will require the use of chemical batteries in conjunction with the local production of renewable electricity. The synthesis of methanol is an important option for chemical batteries and will, for that reason, be described here in detail. It is also shown that the necessary, robust, and fundamental understanding of processes and the material science of catalysts for the hydrogenation of CO₂ does not yet exist.

Identifying the nature of the active sites in methanol synthesis over Cu/ZnO/Al2O3 catalysts

The heterogeneously catalysed reaction of hydrogen with carbon monoxide and carbon dioxide (syngas) to methanol is nearly 100 years old, and the standard methanol catalyst Cu/ZnO/Al2O3 has been applied for more than 50 years. Still, the nature of the Zn species on the metallic Cu0 particles (interface sites) is heavily debated. Here, we show that these Zn species are not metallic, but have a positively charged nature under industrial methanol synthesis conditions. Our kinetic results are based on a self-built high-pressure pulse unit, which allows us to inject selective reversible poisons into the syngas feed passing through a fixed-bed reactor containing an industrial Cu/ZnO/Al2O3 catalyst under high-pressure conditions. This method allows us to perform surface-sensitive operando investigations as a function of the reaction conditions, demonstrating that the rate of methanol formation is only decreased in CO2-containing syngas mixtures when pulsing NH3 or methylamines as basic probe molecules.

Influence of gas impurities on the hydrogenation of CO2 to methanol using indium-based catalysts

In this study, the performance of an In₂O₃/ZrO₂ catalyst for hydrogenation of CO₂ to methanol is reported in the presence of typical impurities of industrial CO₂ feed gas streams.