In its sixth assessment report published in 2022, the Intergovernmental Panel on Climate Change (IPCC) cites carbon capture and utilization as a suitable solution for mitigating climate change for the first time. Several future scenarios for a net-zero chemical industry by 2050 show that between 10 and 30% of the demand for product-bound carbon will come from the use ofCO2.
CO2-based methanol as a fuel or polymer building block
Methanol based onCO2 is currently one of the most advanced and promising (Carbon Capture and Utilization) CCU technologies for the production of fuels and chemical feedstocks. This technology can be used as a storage system for solar and wind energy or as a feedstock for renewable chemicals (e.g. formaldehyde) or polymers (via methanol-to-olefins technology). Methanol can also be used as a fuel additive and is of great interest to the shipping industry as an alternative fuel for ships. It can successfully replace heavy fuel oil without the need to replace engines. The nova-Institute has identified around 25 companies developingCO2-based methanol, mostly based onCO2 hydrogenation, some of them developing electrochemical processes. In 2011, the pioneering company Carbon Recycling International (CRI) in Iceland commissioned a methanol pilot plant with a capacity of 4,000 t/a. In 2022, a new plant based on the technology licensed from CRI was commissioned in China. Two further new plants are scheduled to go into operation in China and Norway by 2025. Many other technology providers and companies have announced plans to build commercial plants with a capacity of 1 megaton (Mt)/a forCO2-based methanol by 2030.
The run onCO2-based hydrocarbons
Many companies are working on the use ofCO2-based syngas using Fischer-Tropsch technologies to produce customizedCO2-based hydrocarbons such as kerosene, diesel, naphtha and waxes. It is currently one of the most advanced technologies for the technical use ofCO2. The focus here is on the kerosene fraction, where the quota for sustainably produced aviation fuels (SAF) is driving forward corresponding projects, securing markets and promoting high levels of investment in European chemical parks. All of these fractions are produced in the course of Fischer-Tropsch processes, which also make other products such as naphtha or waxes available to the chemical industry. Waxes in particular achieve good market prices.
One of the first commercial plants based onCO2-based Fischer-Tropsch hydrocarbons is scheduled to go into operation in 2025 and will be operated by the Norwegian company Nordic Electrofuel. The company plans to commission a plant with a capacity of 10 ml/a and gradually expand it in the future. The nova-Institute identified a total of 15 companies that are developingCO2-based hydrocarbons. These are either technology providersof CO2-based synthesis technologies that use Fischer-Tropsch technology for the commercial production of fuels or companies that use technologies from other providers to create added value from their emissions, as well as consortium projects.
Biotechnological and electrochemical conversion to expand the range ofCO2-based chemicals
BiotechnologicalCO2 conversion continues to be of great interest and offers great potential for the production of numerous chemical precursors and polymers. The nova-Institute has identified 13 companies active in the biotechnological conversion ofCO2 into chemicals. The main players have a large portfolio and could offer chemicals such as methane, ethanol, lactic acid or butanol. One of the most advanced technologies in this area is LanzaTech, which currently operates three commercialCO2-based ethanol plants in China and Belgium, which are used for fuel and ethylene synthesis. Another is Electrochaea, which produces methane that can be fed into the natural gas grid. Electrochaea has several industrial-scale pilot plants in Europe and the USA and aims to produce more than 320,000 tons of methane per year by 2025.
In recent years, numerous improvements have been made in the electrochemical conversion ofCO2 into chemicals, leading to increasing interest from key players and the creation of several start-ups in this field. The nova-Institute identified 18 companies active in this development area, focusing primarily on CO (or syngas), methanol, formic acid or ethylene. Many pilot plants are already in operation. CO (or synthesis gas) production via this route will soon be used in a commercial plant, combined with Fischer-Tropsch technology, to produce hydrocarbons.
MainCO2 use for polymers
Several suppliers are already makingCO2-based polycarbonates commercially available. One of the largest volumes available is aromatic polycarbonates (PC) based on technology licensed from Asahi Kasei. The total production capacity of about 900 kilotons (kt)/a of aromatic PC represents about 16% of the global aromatic PC production capacity. In addition, several companies worldwide offer aliphatic polycarbonates such as polypropylene carbonate (PPC) for a wide range of applications. High molecular weight versions are used for thermoplastic applications, while low molecular weight versions are used as polycarbonate polyols and are used in the polyurethane (PU) sector as foams or coatings. TheCO2 content of these polymer types can be up to 50 percent by weight. The nova-Institute has identified 14 companies that are developingCO2-based polycarbonates for various applications. Most of these companies are based in Asia.
In addition, five companies have been identified that are developingCO2-based polyhydroxyalkanoates (PHA), with one company, Newlight Technologies, having reached commercial capacity and planning to expand this by 2024. ManyCO2-based chemicals can be used for polymer applications, at the same time some companies are working on projects targeting this end use.
Food and feed fromCO2-based proteins
Single cell proteins (SCP) describe microorganisms or isolated proteins that are synthesized microbially. Microorganisms are not only capable of producing large amounts of proteins (up to 70%), but also provide large amounts of fatty acids, vitamins and mineral salts. They can be used as animal feed and for human consumption.CO2-based SCPs can be a promising alternative to meet the growing protein demand while avoiding an increase in animal feed for animal-based protein production. The nova-Institute has identified 13 companies that are developingCO2-based proteins based on biotechnological conversion. These companies are mainly located in Europe and North America. Some technologies have reached pilot scale, while the first commercial plant is scheduled to open in 2023 by the company Solar Foods in Finland.
Building withCO2-based minerals
Ex-situ mineralization or enhanced rock weathering (ERW) can be used in laboratory environments or industrial plants. There are currently several technologies on the market that use the carbonation process to produce substitute products for the cement industry. Industrial waste such as blast furnace and steel slag can be used as a starting material. These technologies enable the production of cement with a lower carbon footprint as an alternative building and construction material. The nova-Institute identified 15 companies that are developing rock weathering-based enhanced mineralization. Most of these companies are based in Europe and North America. Some technologies have already reached commercial scale, such as the company GreenOre, and are often used in conjunction with other industrial waste sources. Several other commercial plants are planned by 2030.
INFO
Fischer-Tropsch synthesis
Fischer-Tropsch synthesis is a large-scale, heterogeneous catalytic polymerization process for the production of hydrocarbons. In this process, carbon monoxide adsorbed on cobalt or iron-containing catalyst surfaces is hydrogenated with hydrogen. The reactions take place at temperatures of around 150 - 300 °C and pressures of 1 - 25 bar. The products of Fischer-Tropsch synthesis are synthetic motor oils and liquid synthetic fuels such as petrol and diesel fuel, which are practically free of sulphur and nitrogen compounds and have lower exhaust emissions than conventional diesel fuel. The resulting longer-chain hydrocarbons are used as a raw material base for the chemical industry or as Fischer-Tropsch wax as an additive in the adhesives industry, for coatings or in polymer processing.
REFERENCES:
De la Garza, A. 2023: The Inflation Reduction Act Includes a Bonanza for the Carbon Capture Industry(www.time.com). Last access 23-03-01. https://time.com/6205570/inflation-reduction-act-carbon-capture/
IPCC 2022: Climate Change 2022 Mitigation of Climate Change. Last access 2022-12. https://www.ipcc.ch/report/ar6/wg3/downloads/report/IPCC_AR6_WGIII_FullReport.pdf
Kähler, F., Porc, O., Carus, M. 2023: RCI Report: Carbon Flows. Compilation of supply and demand of fossil and renewable carbon on a global and European level. Renewable Carbon Initiative, February 2023 (Ed.), Download at www.renewable-carbon-initiative.com
