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1CO2 UTILIZATION FFPAG Fig. 29: Sankey diagrams (qualitative) for visualising the carbon footprints for the combined methane-steam reforming and coking plant process using the best available technology (left) and for the new FfPaG concept (right). gases (FfPaG). The process comprises the pyrolysis of natural gas to form hy- drogen and granular carbon, the catalytic conversion of the hydrogen and CO2 to produce syngas (CO2 activation) and controlling the size and morphology of the carbon product. The hydrogen, whether generated directly from pyrolysis or after CO2 activation to form syngas, can be utilised by the chemical industry and for the production of transport fuels. The granular carbon can be used as a high-quality feedstock for a variety of applications in the coke and steel pro- duction sectors, as well as for other metallurgical processes. Figure 28 shows the new process and the component stages: methane pyrol- ysis, production and control of the granular carbon, and catalytic CO2 acti- vation via the reverse water-gas shift reaction (RWGS). The granular carbon can be used as a substitute for coal in coking plants and in blast furnaces, or as replacement for petroleum coking the alumini- um smelting industry – all of which lead to an improvement in the carbon footprint of the overall process. Global demand for coking coal is estimat- ed at approximately 1 billion metric tons per year – the largest single in- dustrial use of carbon. The fabrication of anodes for use in the aluminium industry accounts for a further 25 million metric tons of carbon annually. Global annual demand for hydrogen and syngas is around 60 million met- ric tons and 220 million metric tons respectively. Methane pyrolysis yields carbon and hydrogen in a mass ratio of 3:1 so that sufficient quantities of carbon could be produced for other applications provided that the carbon can be produced at a high enough level of purity. The successful commercial implementation of the process will depend on the site-dependent levels of State of the art CO2 Heat Combustion Coke oven gas Novel process concept CO2 Heat Combustion Coking plant Production and transport Coal CO2 Hydrogen Methane steam reforming Metallurgical coke CO2 CO2 Electricity mix 2030 CO2 Hydrogen Methane pyrolysis Production and transport Natural gas Coking plant Production and transport Coal Electricity Metallurgical coke CO2 CO2 and transport Natural gas Production 50 % reduction of CO2-emissions during the production of hydrogen, metallurgical coke and heat 82PDF Image | Chemical Processes and Use of CO2
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