Process synthesis of hybrid coal, biomass, and natural gas to liquids via Fischer–Tropsch synthesis, ZSM-5 catalytic conversion, methanol synthesis, methanol-to-gasoline, and methanol-to-olefins/distillate technologies

Recent advances in bifunctional synthesis gas conversion to chemicals and fuels with a comparison to monofunctional processes

In order to meet the climate goals of the Paris Agreement and limit the potentially catastrophic consequences of climate change, we must move away from the use of fossil feedstocks for the production of chemicals and fuels. The conversion of synthesis gas (a mixture of hydrogen, carbon monoxide and/or carbon dioxide) can contribute to this. Several reactions allow to convert synthesis gas to oxygenates (such as methanol), olefins or waxes. In a consecutive step, these products can be further converted into chemicals, such as dimethyl ether, short olefins, or aromatics. Alternatively, fuels like gasoline, diesel, or kerosene can be produced. These two different steps can be combined using bifunctional catalysis for direct conversion of synthesis gas to chemicals and fuels. The synergistic effects of combining two different catalysts are discussed in terms of activity and selectivity and compared to processes based on consecutive reaction with single conversion steps. We found that bifunctional catalysis can be a strong tool for the highly selective production of dimethyl ether and gasoline with high octane numbers. In terms of selectivity bifunctional catalysis for short olefins or aromatics struggles to compete with processes consisting of single catalytic conversion steps.

Economic and Environmental Performance of an Integrated CO2 Refinery

The consequences of global warming call for a shift to circular manufacturing practices. In this context, carbon capture and utilization (CCU) has become a promising alternative toward a low-emitting chemical sector. This study addresses for the first time the design of an integrated CO₂ refinery and compares it against the business-as-usual (BAU) counterpart. The refinery, which utilizes atmospheric CO₂, comprises three synthesis steps and coproduces liquefied petroleum gas, olefins, aromatics, and methanol using technologies that were so far studied decoupled from each other, hence omitting their potential synergies. Our integrated assessment also considers two residual gas utilization (RGU) designs to enhance the refinery's efficiency. Our analysis shows that a centralized cluster with an Allam cycle for RGU can drastically reduce the global warming impact relative to the BAU (by ≈135%) while simultaneously improving impacts on human health, ecosystems, and resources, thereby avoiding burden-shifting toward human health previously observed in some CCU routes. These benefits emerge from (i) recycling CO₂ from the cycle, amounting to 11.2% of the total feedstock, thus requiring less capture capacity, and (ii) reducing the electricity use while increasing heating as a trade-off. The performance of the integrated refinery depends on the national grid, while its high cost relative to the BAU is due to the use of expensive electrolytic H₂ and atmospheric CO₂ feedstock. Overall, our work highlights the importance of integrating CCU technologies within chemical clusters to improve their economic and environmental performance further.

Low-Grade Thermal Energy Harvesting and Self-Powered Sensing Based on Thermogalvanic Hydrogels

Thermoelectric cells (TEC) directly convert heat into electricity via the Seebeck effect. Known as one TEC, thermogalvanic hydrogels are promising for harvesting low-grade thermal energy for sustainable energy production. In recent years, research on thermogalvanic hydrogels has increased dramatically due to their capacity to continuously convert heat into electricity with or without consuming the material. Until recently, the commercial viability of thermogalvanic hydrogels was limited by their low power output and the difficulty of packaging. In this review, we summarize the advances in electrode materials, redox pairs, polymer network integration approaches, and applications of thermogalvanic hydrogels. Then, we highlight the key challenges, that is, low-cost preparation, high thermoelectric power, long-time stable operation of thermogalvanic hydrogels, and broader applications in heat harvesting and thermoelectric sensing.

Exergy Analysis of Alternative Configurations of Biomass-Based Light Olefin Production System with a Combined-Cycle Scheme via Methanol Intermediate

Thermodynamic performance of three conceptual systems for biomass-derived olefin production with electricity cogeneration was studied and compared via exergy analysis at the levels of system, subsystem and operation unit. The base case was composed of the subsystems of gasification, raw fuel gas adjustment, methanol/light olefin synthesis and steam & power generation, etc. The power case and fuel case were designed as the combustion of a fraction of gasification gas to increase power generation and the recycle of a fraction of synthesis tail gas to increase olefin production, respectively. It was found that the subsystems of gasification and steam & power generation contribute ca. 80% of overall exergy destruction for each case, of which gasifier and combustor are the main exergy destruction sources, due to the corresponding chemical exergy degrading of biomass and fuel gas. The low efficiency of 33.1% for the power case could be attributed to the significant irreversibility of the combustor, economizer, and condenser in the combined-cycle subsystem. The effect of the tail gas recycle ratio, moisture content of feedstock, and biomass type was also investigated to enhance system exergy performance, which could be achieved by high recycle ratio, using dry biomass and the feedstock with high carbon content. High system efficiency of 38.9% was obtained when oil palm shell was used, which was 31.7% for rice husk due to its low carbon content.

Modelling and Cost Estimation for Conversion of Green Methanol to Renewable Liquid Transport Fuels via Olefin Oligomerisation

The ambitious CO2 emission reduction targets for the transport sector set in the Paris Climate Agreement require low-carbon energy solutions that can be commissioned rapidly. The production of gasoline, kerosene, and diesel from renewable methanol using methanol-to-olefins (MTO) and Mobil’s Olefins to Gasoline and Distillate (MOGD) syntheses was investigated in this study via process simulation and economic analysis. The current work presents a process simulation model comprising liquid fuel production and heat integration. According to the economic analysis, the total cost of production was found to be 3409 €/tfuels (273 €/MWhLHV), corresponding to a renewable methanol price of 963 €/t (174 €/MWhLHV). The calculated fuel price is considerably higher than the current cost of fossil fuels and biofuel blending components. The price of renewable methanol, which is largely dictated by the cost of electrolytic hydrogen and renewable electricity, was found to be the most significant factor affecting the profitability of the MTO-MOGD plant. To reduce the price of renewable fuels and make them economically viable, it is recommended that the EU’s sustainable transport policies are enacted to allow flexible and practical solutions to reduce transport-related emissions within the member states.

A framework to predict the price of energy for the end-users with applications to monetary and energy policies

Energy affects every single individual and entity in the world. Therefore, it is crucial to precisely quantify the “price of energy” and study how it evolves through time, through major political and social events, and through changes in energy and monetary policies. Here, we develop a predictive framework, an index to calculate the average price of energy in the United States. The complex energy landscape is thoroughly analysed to accurately determine the two key factors of this framework: the total demand of the energy products directed to the end-use sectors, and the corresponding price of each product. A rolling horizon predictive methodology is introduced to estimate future energy demands, with excellent predictive capability, shown over a period of 174 months. The effectiveness of the framework is demonstrated by addressing two policy questions of significant public interest.

Global energy transformation requires quantifying the "price of energy" and studying its evolution. Here the authors present a predictive framework that calculates the average US price of energy, estimating future energy demands for up to four years with excellent accuracy, designing and optimizing energy and monetary policies.

Research advances on process systems integration and process safety in China

Process systems engineering research focuses on the planning, design, operation, and safety of process systems rather than unit operations. In response to the rapid growth of the chemical process industry in the last 20 years in China, advanced system integration and process safety technologies are investigated and applied for better resource utilization, less environmental impact, and safer working places. In this regard, the review in this article consists of four main achievements: (1) process synthesis, (2) energy system integration, (3) water system integration, and (4) process safety management. The purpose of process synthesis and integration is to improve resource and energy utilization, at the same time lowering by-products and emissions. Optimization is conducted on process structure and operation, following the principles of resource coupling and energy cascade utilization. Typical examples are coupling of coal and hydrogen-rich resources and integration of coal-based polygeneration process of chemicals, electricity, and heat. Energy integration implements the coordinated optimization of total site energy systems. Reviews are made on specific methodologies based on the thermodynamics and applications of design and retrofit in ethylene, oil refining, and synthetic ammonia industries. There are energy savings by 10%–20% and yields increasing by 20%–30%. In addition, waste heat recovery and cold energy utilization are also important research areas. Reviews on the progress of water system integration and its industrial applications are also conducted. It includes the direct reuse, regeneration, and reuse/recycle in water systems and systems with internal water mains. Finally, safety management and technologies are also indispensable technological advancements of the process. The legislation system and the work safety-related standard system have been gradually established and enforced. Process safety research progress is reviewed, and questions are proposed for improving the accident prevention and safety management agenda.

Synergistic photothermal and photochemical partial oxidation of methane over noble metals incorporated in mesoporous silica

We establish a hot-carrier-driven photothermal and photochemical system for partial oxidation of methane using noble metals incorporated in mesoporous silica.

Low-Temperature Steam Reforming of Natural Gas after LPG-Enrichment with MFI Membranes

Low-temperature hydrogen production from natural gas via steam reforming requires novel processing concepts as well as stable catalysts. A process using zeolite membranes of the type MFI (Mobile FIve) was used to enrich natural gas with liquefied petroleum gas (LPG) alkanes (in particular, propane and n-butane), in order to improve the hydrogen production from this mixture at a reduced temperature. For this purpose, a catalyst precursor based on Rh single-sites (1 mol% Rh) on alumina was transformed in situ to a Rh1/Al2O3 catalyst possessing better performance capabilities compared with commercial catalysts. A wet raw natural gas (57.6 vol% CH4) was fully reformed at 650 °C, with 1 bar absolute pressure over the Rh1/Al2O3 at a steam to carbon ratio S/C = 4, yielding 74.7% H2. However, at 350 °C only 21 vol% H2 was obtained under these conditions. The second mixture, enriched with LPG, was obtained from the raw gas after the membrane process and contained only 25.2 vol% CH4. From this second mixture, 47 vol% H2 was generated at 350 °C after steam reforming over the Rh1/Al2O3 catalyst at S/C = 4. At S/C = 1 conversion was suppressed for both gas mixtures. Single alkane reforming of C2–C4 showed different sensitivity for side reactions, e.g., methanation between 350 and 650 °C. These results contribute to ongoing research in the field of low-temperature hydrogen release from natural gas alkanes for fuel cell applications as well as for pre-reforming processes.

Syngas production from pyrolysis of nine composts obtained from nonhybrid and hybrid perennial grasses

A pyrolysis of compost for the production of syngas with an explicit H2/CO = 2 or H2/CO = 3 was investigated in this study. The composts were obtained from nonhybrid (perennial) grasses (NHG) and hybrid (perennial) grasses (HG). Discrepancies in H2 evolution profiles were found between NHG and HG composts. In addition, positive correlations for NHG composts were obtained between (i) H2 yield and lignin content, (ii) H2 yield and potassium content, and (iii) CO yield and cellulose content. All composts resulted in H2/CO = 2 and five of the nine composts resulted in H2/CO = 3. Exceptionally large higher heating values (HHVs) of pyrolysis gas, very close to HHVs of feedstock, were obtained for composts made from mountain brome (MB, 16.23 MJ/kg), hybrid Becva (FB, 16.45 MJ/kg), and tall fescue (TF, 17.43 MJ/kg). The MB and FB composts resulted in the highest syngas formation with H2/CO = 2, whereas TF compost resulted in the highest syngas formation with H2/CO = 3.

Energy Supply Chain Optimization of Hybrid Feedstock Processes: A Review

The economic, environmental, and social performances of energy systems depend on their geographical locations and the surrounding market infrastructure for feedstocks and energy products. Strategic decisions to locate energy conversion facilities must take all upstream and downstream operations into account, prompting the development of supply chain modeling and optimization methods. This article reviews the contributions of energy supply chain studies that include heat, power, and liquid fuels production. Studies are categorized based on specific features of the mathematical model, highlighting those that address energy supply chain models with and without considerations of multiperiod decisions. Studies that incorporate uncertainties are discussed, and opportunities for future research developments are outlined.