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CO2RRECT FUNDED PROJECTS minimised soot formation. An appropriate catalyst was developed by the ac- ademic project partners (Universities of Aachen, Bochum, Dortmund, Dres- den and Stuttgart, the Max Planck Society, the Leibniz Institute for Cataly- sis at the University of (LIKAT), the Karlsruhe Institute of Technology and the INVITE Research Centre). To reduce energy consumption a new heat- ing concept was also needed and this was developed over the course of the project. The chemical reactor was then designed on the basis of these initial developments. A particularly important aspect of the reactor’s design was thermal efficiency and the use of thermally stable materials. A demonstrator was built that incorporated the newly developed heating system. The results showed that the catalyst-loaded heating coils exhibited excellent activity in the reforming reaction and that a single coil was able to achieve conversion rates of 20–30%. The layer activities originally estimated were based on a lay- er thickness of 10 μm and a washcoat efficiency of 100%. It could be shown that a thicker layer yielded a sevenfold increase in catalytic activity. A pro- duction-scale reactor is therefore likely to operate effectively with a signifi- cantly smaller numbers of reaction stages. One of the main project objectives was to evaluate the processes that had been developed under realistic operating scenarios (BTS). The base scenario select- ed was supplying a 400 ktpa MDI plant with H2 and CO. The capital invest- ment needed to implement the candidate technologies for producing carbon monoxide and hydrogen proved to be extraordinarily high. This was due to: • the high specific costs of the water electrolysis process and • the need to install an electrolysis unit with a very high power rating that will be able to exploit the temporary availability of excess electrical energy. The payback period for such a large capital investment is corresponding- ly long and makes assumptions about the long-term pricing structures for electricity and natural gas. ITT in Aachen evaluated environmental aspects of the technology such as the global warming potential (GWP) and fossil depletion potential (FDP). It could be shown that the CO2RRECT processes have the potential to reduce greenhouse gas emissions and to lower consumption of fossil resources rel- ative to the standard benchmark. The maximum achievable reduction in greenhouse gas emissions associated with the production of 109.4 kt of syn- thesis gas and 161.2 GWh of electricity are about 200 kt CO2 per year. 147PDF Image | Chemical Processes and Use of CO2
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