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1CO2 UTILIZATION Aachen University showed that the carbon footprint of the overall process was significantly lower than that of the reference process. A key factor be- hind the reduced carbon footprint was the partial replacement of the fos- sil-based epoxides by CO2. A pilot plant was built and operated in Leverkusen as part of a second pro- ject ‘Dream Production’. Once the pilot plant’s test phase had been complet- ed successfully, COVESTRO funded its own commercial plant in Dormagen, which went on stream in 2016. The product is a novel polyol containing about 20 % CO2. The polyol is a central component for synthesising a poly- urethane foam that will be used in the manufacture of foam mattresses. The commercial plant in Dormagen has an annual production capacity of 5000 metric tons of polyether carbonate polyol. The CO2 used in the produc- tion of the polyol comes from an ammonia-producing plant operated on the same site by the company Ineos. But COVESTRO is not the only company currently implementing poly- mer production projects: in the USA, NOVOMER is operating a commercial plant for polycarbonates and polyols; in Japan between 65 and 260 kilotons of bisphenol-A polycarbonate is being produced annually in five commer- cial plants; and in China, Jinlong-Cas Chemical Co. operates a facility that produces 10,000 metric tons of poly(propylene carbonate) per year. Poten- tial global demand for poly(propylene carbonate) has been estimated to be around 50,000 metric tons annually. 1.1.2.2.2.2 Synthetic fuels The production of synthetic fuels is a very promising area for the chemical utilisation of CO2. If it was possible to manufacture all liquid fuels from CO2, their production would require 3–5 billion metric tons of CO2 globally per year depending on actual future levels of fuel demand. Another particularly appealing feature of CO2-based fuels is that they can be introduced into an existing market infrastructure. As already mentioned, synthetic fuels can al- so be used as chemical systems for storing excess electricity from renewable energy sources, thus providing the necessary temporary and spatial flexibil- ity to manage energy supply bottlenecks. Demonstration units that use CO2 as a chemical building block in the production of synthetic diesel, synthetic petrol, kerosene, methane and methanol are already in existence. At present, the processes that play a key role in the production of CO2-based liquid fuels are hydrogen production by electrolysis, the generation of syn- thesis gas (syngas) via the reverse watergas shift reaction (RWGS) and sub- sequent chemical conversion processes, such as the Fischer-Tropsch reac- tion. Hydrogen (H2) is an essential component in the production of synthetic fuels, as it is needed to chemically reduce the CO2. In the electrolysis of wa- 24PDF Image | Chemical Processes and Use of CO2
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