Design of a Production Process for Poly(oxymethylene) Dimethyl Ethers from Dimethyl Ether and Trioxane

Advancements and Challenges in the Synthesis of Oxymethylene Ethers (OMEs) as Sustainable Transportation Fuels

The urgent need for sustainable alternatives to fossil fuels in the transportation sector is driving research into novel energy carriers that can meet the high energy density requirements of heavy-duty vehicles without exacerbating the climate change. This concept article examines the synthesis, mechanisms, and challenges associated with oxymethylene ethers (OMEs), a promising class of synthetic fuels potentially derived from carbon dioxide and hydrogen. We highlight the importance of OMEs in the transition towards non-fossil energy sources due to their compatibility with the existing Diesel infrastructure and their cleaner combustion profile. The synthesis mechanisms, including the Schulz-Flory distribution and its implications for OME chain length specificity, and the role of various catalysts and starting materials are discussed in depth. Despite advancements in the field, significant challenges remain, such as overcoming the Schulz-Flory distribution, efficiently managing water as an undesirable byproduct, and improving the overall energy efficiency of the OME synthesis. Addressing these challenges is crucial for OMEs to become a viable alternative fuel, contributing to the reduction of greenhouse gas emissions and the transition to a sustainable energy future in the transportation sector.

Process Intensification Strategies for Power-to-X Technologies

Sector coupling remains a crucial measure to achieve climate change mitigation targets. Hydrogen and Power-to-X (PtX) products are recognized as major levers to allow the boosting of renewable energy capacities and the consequent use of green electrons in different sectors. In this work, the challenges presented by the PtX processes are addressed and different process intensification (PI) strategies and their potential to overcome these challenges are reviewed for ammonia (NH3), dimethyl ether (DME) and oxymethylene dimethyl ethers (OME) as three exemplary, major PtX products. PI approaches in this context offer on the one hand the maximum utilization of valuable renewable feedstock and on the other hand simpler production processes. For the three discussed processes a compelling strategy for efficient and ultimately maintenance-free chemical synthesis is presented by integrating unit operations to overcome thermodynamic limitations, and in best cases eliminate the recycle loops. The proposed intensification processes offer a significant reduction of energy consumption and provide an interesting perspective for the future development of PtX technologies.

Future Power Train Solutions for Long-Haul Trucks

Achieving the CO2 reduction targets for 2050 requires extensive measures being undertaken in all sectors. In contrast to energy generation, the transport sector has not yet been able to achieve a substantive reduction in CO2 emissions. Measures for the ever more pressing reduction in CO2 emissions from transportation include the increased use of electric vehicles powered by batteries or fuel cells. The use of fuel cells requires the production of hydrogen and the establishment of a corresponding hydrogen production system and associated infrastructure. Synthetic fuels made using carbon dioxide and sustainably-produced hydrogen can be used in the existing infrastructure and will reach the extant vehicle fleet in the medium term. All three options require a major expansion of the generation capacities for renewable electricity. Moreover, various options for road freight transport with light duty vehicles (LDVs) and heavy duty vehicles (HDVs) are analyzed and compared. In addition to efficiency throughout the entire value chain, well-to-wheel efficiency and also other aspects play an important role in this comparison. These include: (a) the possibility of large-scale energy storage in the sense of so-called ‘sector coupling’, which is offered only by hydrogen and synthetic energy sources; (b) the use of the existing fueling station infrastructure and the applicability of the new technology on the existing fleet; (c) fulfilling the power and range requirements of the long-distance road transport.

Property Data Estimation for Hemiformals, Methylene Glycols and Polyoxymethylene Dimethyl Ethers and Process Optimization in Formaldehyde Synthesis

Polyoxymethylene dimethyl ethers (OMEn) are frequently discussed as alternative diesel fuels, with various synthesis routes considered. OME3–5 syntheses demand significant amounts of thermal energy due to the complex separation processes that they entail. Therefore, innovative process designs are needed. An important tool for the development of new processes is process simulation software. To ensure sound process simulations, reliable physico-chemical models and component property data are necessary. Herein we present the implementation of a state-of-the-art thermodynamic model to describe the component systems of formaldehyde-water and formaldehyde-methanol using Microsoft® Excel (2010, Microsoft Corp, Redmond, WA, USA) and Aspen Plus®, (V8.8, Aspen Tech, Bedford, MA, USA) determine the deviation between the calculated results and experimental literature data, and minimize the deviation by means of parameter fitting. To improve the accuracy of the estimation of the missing property data of hemiformals and methylene glycols formed from formaldehyde using group contribution methods, the normal boiling points were estimated based on molecular analogies. The boiling points of OME6-10 are determined through parameter regression in accordance with the vapor pressure equation. As an application example, an optimization of the product separation of the state-of-the-art formaldehyde synthesis is presented that helps decrease the losses of methanol and formaldehyde in flue gas and wastewater.

A Force Field for Poly(oxymethylene) Dimethyl Ethers (OMEn)

A united atom force field for the homologous series of the poly(oxymethylene) dimethyl ethers (OMEn), H₃C-O-(CH₂O)_n-CH₃, is presented. OMEn are oxygenates and promising new synthetic fuels and solvents. The molecular geometry of the OMEn, the internal degrees of freedom, and their electrostatic properties were obtained from quantum mechanical calculations. To model repulsion and dispersion, Lennard-Jones parameters were fitted to the experimental liquid densities and vapor pressures of pure OMEn (n = 1-4). The critical properties of OMEn (n = 1-4) were determined from the simulation data. Additionally, the shear viscosity of pure liquid OMEn is evaluated and compared with literature data. Finally, the solubility of CO₂ in OME2, OME3, and OME4 is predicted using a literature model for CO₂ and the Lorentz-Berthelot combining rules. The results agree well with experimental data from the literature.