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EXECUTIVE SUMMARY Carbon dioxide utilisation for the production of fuels, chemicals and materials has the potential to be part of the CO2 abatement options of the future, decreasing CO2 emissions and entailing less fossil fuel consumption. It is a promising source of competitive advantage for the European industry. In order to contribute to the on-going debate regarding the potential of CO2 utilisation as a CO2 mitigation tool and the competitiveness of carbon utilisation processes, the JRC assessed five products: methanol, formic acid, urea, aggregate for concrete, and polyethercarbonate polyol for polyurethanes. The current report addresses methanol and formic acid. Carbon dioxide utilisation (CDU) stands in this document for the CO2 transformation process into another product with commercial value. This study performs a technological, economic and environmental evaluation, and calculates the potential emissions abatement of two processes that synthesise methanol and formic acid from CO2, following a process system engineering (PSE) approach. The results aim at evaluating the competitiveness of each process at plant scale and answering the following questions: Under what economic conditions would the CDU plant become profitable, as they are not yet fully commercial? What is the potential to reduce CO2 emissions, in tonnes of CO2 per tonne of product and per year, from (i) a plant point of view, if compared to benchmark synthesis processes to produce methanol and formic acid, and from (ii) a market point of view? The latter takes into account the prospects in sectors such as the chemical industry, transport and energy. Methanol synthesis from H2 and captured CO2 is currently under development, with experience at pilot and demonstration scales by Carbon Recycling International (CRI) and Mitsui Chemicals Inc. Formic acid synthesis from CO2 and H2 is still in its infancy. Different patents have been acquired by companies like BP and BASF on the catalytic transformation of CO2 and H2 into formic acid. Det Norske Veritas (DNV) and Mantra Venture Group have a small-scale demonstration plant and a pilot plant project on the electro-catalytic reduction of water and CO2 to formic acid, respectively. Conventional methanol plants in Europe use natural gas and heavy liquid oil as raw material, with an average size of 450 kt of methanol per year. Current conventional formic acid plants may range from 100 to 20 kt of formic acid per year. The most common synthesis process is the hydrolysis of methyl formate. In order to investigate the competitiveness of each CDU process, the methodology established focused on the CDU plant layout, its feedstock and products. No further process is considered, either upstream or downstream of the plant (e.g. CO2 capture or product distribution and consumption). With the aim of determining the net amount of CO2 emissions prevented, each CDU plant is compared to its equivalent conventional plant. While the feedstock to the CDU processes to synthesise methanol and formic acid are CO2 and water to produce H2, the feedstock to the benchmark conventional plants are fossil fuels, natural gas and heavy fuel oil in these particular processes. This work utilises process flow modelling, with simulations developed in CHEMCAD, to obtain the energy and mass balances, the total purchase cost of the equipment of both CDU plants and all the derived indicators for the technological, economic and environmental evaluation, this last based on a CO2 balance. From the modelling task, the net present value (NPV) and the tonnes of CO2 consumed per tonne of product are the main input for financial and market analyses. As for the prediction of road transport penetration pathways, the in-house Powertrain Technology Transition Market Agent Model (PTTMAM) is used to depict the market in the year 2030. 1. Each CDU process model is developed based on public data from research reports, peer reviewed papers and/or patents. If data are not available, the hypotheses assumed by the 11PDF Image | evaluation of CO2 utilisation for fuel production
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