Life cycle analysis of coal based methanol-to-olefins processes in China

On the FT-ICR mass spectrometry analysis of dissolved organic matter released by adsorbent during coal chemical wastewater treatment

This study analyzed the dissolved organic matter (DOM) released by adsorbent during wastewater treatment. It was found that the adsorption method resulted in an organic removal efficiency of over 97 % for coal-to-olefin (CTO) wastewater, with the lowest value of 15.7 mg/L. The Fourier Transform Ion Cyclotron Resonance Mass Spectrometry (FT-ICR MS) detected 4111 DOM in the wastewater, 4052 remaining DOM after first-stage anthracite (ANC) adsorption, and 1013 after second-stage macroporous adsorption resin (MAR). The removal degree of lipids in wastewater was the highest, followed by aliphatic/amino-acid/mini-peptides and lignin. During the adsorption process, the proportion of halogenated compounds (HCs) declined from 59.86 % to 38.63 % and 21.67 %. Additionally, freshly produced 2035 and 311 DOMs were found in the adsorption effluent of ANC and MAR, respectively, with HCs accounting for 34.71 % and 67.96 %. Upon flowing ultra-pure water through ANC and MAR, the effluent dissolved organic carbon (DOC) ranges were 1.118-3.574 mg/L and 1.014-2.557 mg/L, respectively. There were 159 and 131 species of DOM detected, respectively, with HCs content of 59.06 % and 45.02 %. Comparative experiments revealed the complex components of the wastewater promoting the release of organic matter on the adsorbent surface that further reacted to generate organic matter. However, fewer substances were released by the adsorbent.

Technological progress and coupling renewables enable substantial environmental and economic benefits from coal-to-olefins

China's growing demand for bulk chemicals and concerns regarding energy security are scaling up coal-to-olefins (CTO) production. Three generations of independent dimethyl ether/methanol-to-olefins technologies have been successively launched with greatly improved production efficiencies. However, to date, widespread concerns regarding the intensive environmental impacts and potential economic risks have not been addressed in the context of this industrialization. Here we show that, through the technological progress from the first to the third generation, life cycle energy consumption, water consumption, and carbon emissions can be reduced to 119.5 GJ/t, 27.6 t/t, and 9.1 t CO2-eq/t, respectively, and human health damage, ecosystem quality damage, and resource scarcity impacts can be decreased by 40.5 %, 50.1 %, and 16.4 %, respectively. This is accompanied by an excellent performance in terms of production cost, net present value, and internal return rate at 792.5 USD/t, 173.4 USD/t, and 19.4 %, respectively. Substantial environmental and economic benefits can be gained by coupling renewables in the form of using green hydrogen from solar and wind power to synthesize methanol. Particularly, life cycle carbon emissions and resource scarcity impacts are reduced by 23.4 % and 22.4 %, respectively, exceeding the reduction in technological progress. However, coupling renewables increases the life cycle energy consumption to 154.5 GJ/t, counteracting the benefits of technological progress. Our results highlight the importance of technological progress and coupled renewables for enhancing the sustainability of the CTO industry.

Approaches to Carbon Emission Reductions and Technology in China’s Chemical Industry to Achieve Carbon Neutralization

Based on China’s goal of achieving carbon neutrality by 2060, this study focused on its coal gasification in 2010–2019. Carbon emissions were calculated from industrial data, and an LMDt model was established to analyze the influencing factors of carbon emissions. Through scenario analysis, the paths of carbon emission reductions in the chemical industry were analyzed, and their emission reduction potential was estimated. The results showed that the carbon emissions in the chemical industry increased rapidly in 2010–2019, reaching 196 million tons in 2019. The emission structure was the most important factor in mitigating carbon emissions, and the emission intensity, industrial structure, economic development level, and labor force scale had different degrees of promotion effects, of which emission intensity was the strongest. The chemical industry can reach a carbon peak before 2030 under the three analyzed scenarios, and the emission reduction potential is the largest under the landing policy scenario. The results showed that carbon capture, usage, and storage (CCUS) technology is key for carbon emission reductions and that it is necessary to adjust the industrial structure, reduce emission intensity, and increase forest carbon sink to achieve carbon neutrality in the chemical industry.

Next generation of polyolefin plastics: improving sustainability with existing and novel feedstock base

Abstract

In this account, we present an overview of existing and emerging olefin production technologies, comparing them from the standpoint of carbon intensity, efficiency, feedstock type and availability. Olefins are indispensable feedstock for manufacture of polyolefin plastics and other base chemicals. Current methods of olefin production are associated with significant CO2 emissions and almost entirely rely of fossil feedstock. In order to assess potential alternatives, technical and economic maturity of six principal olefin production routes are compared in this paper. Coal (brown), oil and gas (grey), biomass (green), recycled plastic (pink) as well as carbon capture and storage (purple) and carbon capture and utilization (blue) technologies are considered. We conclude that broader adoption of biomass based “green” feedstock and introduction of recycled plastic based olefins may lead to reduced carbon footprint, however adoption of best available technologies and introduction of electrocracking to existing fossil-based “grey” olefin manufacture process can be the way to achieve highest impact most rapidly. Adoption of Power-to-X approaches to olefins starting from biogenic or atmospheric CO2 and renewable H2 can lead to ultimately carbon–neutral “blue” olefins in the long term, however substantial development and additional regulatory incentives are necessary to make the solution economically viable.

Article highlights

Cooperative physical separation of oil and suspended solids from methanol-to-olefin wastewater: A pilot study

Methanol-to-olefin (MTO) is an important non-petroleum chemical process for the preparation of light olefins. However, the MTO process consumes copious amounts of water and produces large amounts of untreated effluent. Therefore, the realization of efficient wastewater treatment and recycling is key to the green low-carbon development of MTO. Here, a cooperative process combining swirl regenerating micro-channel separation (SRMS) and combined fibrous coalescence (CFC) technologies was proposed to separate high contents of oil and suspended matter in MTO wastewater. Using a pilot device with a treatment capacity of 1 m3/h, the average oil content in MTO wastewater decreased from 750 mg/L to <30 mg/L, while the average content of suspended matter decreased from 108 mg/L to <15 mg/L. Compared with a commercial MTO wastewater treatment process (olefin production capacity of 0.6 million tons per annum), the proposed method could reduce wastewater discharges and costs by 57% and US$ 0.23 million per annum respectively. Equipment costs and operational energy consumption were also reduced by 30% and >95% respectively. The combined process may provide the basis for the green and sustainable treatment of MTO wastewater and its recycling.

Environmental Burdens of China's Propylene manufacturing: Comparative life-cycle assessment and scenario analysis

China's propylene feedstock shifts from oil to imported cheap propane and local coal. However, the associated environmental loads of this feedstock change have seldom been investigated for China's propylene industry. Herein, environmental impacts of the four typical propylene production routes, coal to olefin (CTO), propane dehydrogenation (PDH), steam cracking (SC), and catalytic cracking (CC) process, were compared by life-cycle-assessment (LCA) methodology. Two metrics, midpoint environmental impacts (including nine indicators) and the comprehensive index of energy conservation and emission reduction (ECER), were adopted for this evaluation. The midpoint-impact indices show the trade-offs across the nine environmental dimensions. Thus, it is not easy to rank the environmental advantage of the four production routes. The ECER indices indicate the highest environmental loads in the CTO process, followed by PDH and the comparable SC and CC routes. Raw materials consumption dominates the environmental burden generations of the PDH, SC, and CC routes. Scenario analysis shows that feedstock shift and capacity growth jointly increase the environmental burdens of China's propylene industry by 27-66% in 2025 and 60-111% in 2030, relative to the 2018 baseline. Notably, global-warming potential inevitably increases due to replacing the conventional oil-fed SC/CC capacity either by coal-fed CTO or by propane-fed PDH route. The findings suggest that the feedstock shift of the propylene industry deserves close attention to promote the environmental sustainability of the Chinese chemical manufacturing industry.

Olive pomace versus natural gas for methanol production: a life cycle assessment

Increasing demand for methanol production and global competition for the use of natural resources are key issues in finding new and environmentally routes for methanol production. In this work, life cycle assessment was performed using the software SimaPro v9 to analyze the environmental impact of methanol production process from olive pomace and compare with natural gas route. The main stages considered in the methanol production from olive pomace were olive production, olive oil extraction, and methanol production. In addition, the methanol production in turn can be divided in three main processes: olive pomace gasification, syngas purification, and methanol production which were also evaluated individually. Finally, the global environmental impacts associated with the methanol production from olive pomace were compared with a conventional methanol production from natural gas. This assessment determined that the production of methanol from the olive pomace had a greater environmental impact for all the categories studied except the one related to the shortage of fossil fuels. These results were directly related to the technical performance of the processes.

Thermodynamic and Economic Analysis of Oxy-Fuel-Integrated Coal Partial Gasification Combined Cycle

A novel partial gasification combined cycle (PGCC) system integrating coal partial gasification, oxy-fuel combustion, combined cycle, and CO₂ separation is proposed. The coal-CO₂ partial gasification technology is introduced in the coal gasification unit, and the oxy-fuel combustion technology is employed in the char combustion unit and gas turbine (GT) unit. The thermodynamic and economic analysis of the proposed system is carried out, showing that both energy and exergy efficiency have an increasing/decreasing tendency when the recycled flue gas (RFG) ratio of char combustion and GT increase. When the RFG ratios of char combustion and GT are 0.43 and 0.34, energy and exergy efficiencies reach maximum values of 48.18 and 45.11%, respectively. The energy efficiency of the PGCC-Oxy system is higher than that of the integrated gasification combined cycle (IGCC)-Oxy system by approximately 3%. It can be concluded from the economic analysis that the total investment on the PGCC-Oxy system is 3272.71 million RMB, and the internal rate of return (IRR) and payback time is 8.07% and 12.38 years, respectively.

Life Cycle Assessment of Renewable Reductants in the Ferromanganese Alloy Production: A Review

This study examined the literature on life cycle assessment on the ferromanganese alloy production route. The environmental impacts of raw material acquisition through the production of carbon reductants to the production of ferromanganese alloys were examined and compared. The transition from the current fossil fuel-based production to a more sustainable production route was reviewed. Besides the environmental impact, policy and socioeconomic impacts were considered due to evaluation course of differences in the production routes. Charcoal has the potential to substantially replace fossil fuel reductants in the upcoming decades. The environmental impact from current ferromanganese alloy production can be reduced by ≥20% by the charcoal produced in slow pyrolysis kilns, which can be further reduced by ≥50% for a sustainable production in high-efficient retorts. Certificated biomass can ensure a sustainable growth to avoid deforestation and acidification of the environment. Although greenhouse gas emissions from transport are low for the ferromanganese alloy production, they may increase due to the low bulk density of charcoal and the decentralized production of biomass. However, centralized charcoal retorts can provide additional by-products or biofuel and ensure better product quality for the industrial application. Further upgrading of charcoal can finally result in a CO2 neutral ferromanganese alloy production for the renewable power supply.

Environmental Impact and Environmental Cost Assessment of Methanol Production from wood biomass

Increasing demand for biofuel production and global competition for the use of natural resources are key factors in finding new and environmentally safe routes for methanol production. In the present study, life cycle assessment was used to analyse the potential environmental impact and environmental cost of a novel methanol production process from wood compared to a conventional processes. Both the novel and the conventional process were divided into three stages: pre-treatment, gasification, and syngas cleaning and methanol synthesis. The environmental impacts were assessed and compared using Simapro 9 (ecoinvent 3.5 database) and the ReCiPe 2016 (World-H) midpoint method. The results, expressed per tonne methanol, showed that the impact categories of global warming potential (GWP) and marine ecotoxicity potential were lower in the novel process in comparison to the conventional process (48.2 kg CO₂ eq. vs. 63.1 kg CO₂ eq., and 4.55 kg 1,4-DCB vs. 6.35 kg 1,4-DCB respectively). However, the novel process had a higher environmental impact in the pre-treatment stage. The results of the sensitivity analysis showed that the GWP of the novel process increased from 48.2 kg CO₂ eq. to 216 kg CO₂ eq. due to the replacement of Na₂CO₃ by K₂CO₃. The human toxicity impact categories showed significant impact on environmental cost. These findings will help relevant industries to reduce their environmental impact and improve the production efficiency of methanol from wood.

A Life Cycle Analysis of Deploying Coking Technology to Utilize Low-Rank Coal in China

At present, the excess capacity in China’s coke industry can be deployed to utilize some low-rank coal, replacing coking coal with potential economic gains, energy efficiency, and environmental benefits. This study presents a life cycle analysis to model these potential benefits by comparing a metallurgical coke technical pathway with technical pathways of gasification coke integrated with different chemical productions. The results show that producing gasification coke is a feasible technical pathway for the transformation and development of the coke industry. However, its economic feasibility depends on the price of cokes and coals. The gasification coke production has higher energy consumption and CO2 emissions because of its lower coke yield. Generally speaking, using gasification coke to produce F-T oils has higher economic benefits than producing methanol, but has lower energy efficiency and higher carbon emissions.

Utilizing FBR to produce olefins from CO reduction using Fe–Mn nanoparticles on reduced graphene oxide catalysts and comparing the performance with SBR

Mn was used as a promoter for Fe nanoparticles (NPs) loaded on reduced graphene oxide (rGO). The prepared catalysts were the unpromoted Fe/rGO catalysts along with two Mn promoted catalysts FeMn16 and FeMn29. These catalysts were used as Fischer–Tropsch catalysts in a Fixed Bed Reactor (FBR). The operating conditions of the reactor, namely temperature, pressure and space velocity, were varied to evaluate the catalyst performance and the olefin productivity. The olefins were produced in maximum yields of 34.5% and 31.3% with FeMn29 at 320 and 340 °C respectively. The ratio of light to heavy olefins was three times higher at 340 °C. The catalysts showed good stability up to 50 h of interrupted operation while varying the conditions at each interruption. The performance of the catalysts in the FBR was compared with a previous investigation carried out in an SBR under identical conditions with the same catalysts. The FBR was found to be more Mn tolerant than the SBR, giving very high conversion activity with high Mn concentrations (FeMn29). The FBR produced olefins in much higher yields than the SBR. The SBR was more selective to light olefins at low temperatures and high Mn loading levels, while the FBR produced light olefins at higher selectivities at high temperatures and high Mn concentrations.

Producing olefin rich products from the FTS reaction in both FBR and SBR reactors using Fe–Mn/rGO catalysts.

Mn–Fe nanoparticles on a reduced graphene oxide catalyst for enhanced olefin production from syngas in a slurry reactor

Fe nanoparticles (NPs) supported on reduced graphene oxide (rGO) nano-sheets were promoted with Mn and used for the production of light olefins in Fischer–Tropsch reactions carried out in a slurry bed reactor (SBR). The prepared catalysts were characterized by X-ray fluorescence (XRF), X-ray diffraction (XRD), transmission electron microscope (TEM), Raman spectroscopy, N₂ physisorption, temperature programmed reduction (TPR) and X-ray photoelectron spectroscopic (XPS) methods. Mn was shown to preferentially migrate to the Fe NP surface, forming a Mn-rich shell encapsulating a core rich in Fe. The Mn shell regulated the diffusion of molecules to and from the catalyst core, and preserved the metallic Fe phase by lowering magnetite formation and carburization, so decreasing water gas shift reaction (WGSR) activity and CO conversion, respectively. Furthermore, the Mn shell reduced H₂ adsorption and increased CO dissociative adsorption which enhanced olefin selectivity by limiting hydrogenation reactions. Modification of the Mn shell thickness regulated the catalytic activity and olefin selectivity. Simultaneously the weak metal–support interaction further increased the migration ability owing to the utilization of a graphene-based support. Space velocities, pressures and operating temperatures were also tested in the reactor to further enhance light olefin production. A balanced Mn shell thickness produced with a Mn concentration of 16 mol Mn/100 mol Fe was found to give a good olefin yield of 19% with an olefin/paraffin (O/P) ratio of 0.77. Higher Mn concentrations shielded the active sites and reduced the conversion dramatically, causing a fall in olefin production. The optimum operating conditions were found to be 300 °C, 2 MPa and 4.2 L g⁻¹ h⁻¹ of 1 : 1 H₂ : CO syngas flow; these gave the olefin yield of 19%.

Mn acted as a promoter by forming a Mn-rich layer around a core rich in Fe. The outer layer hindered the formation of magnetite, and impeded H₂ adsorption whilst encouraging CO dissociative adsorption, which gave the perfect conditions for olefin production.