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by-product to dispose of, and an amount of O2 produced from the electrolysis process, sold as a by- product. Due to the proposed integrated CDU flowsheet that burns the purge gases and take advantage of their calorific values to generate power in the four expanders, there is an amount of air that enters the system, and the consequent flue gas that leaves it. The total electricity consumption results from the needs of compression (CO2, H2 streams and gas recycling) and water circulation (a system of pumps), reduced by the ad hoc electricity generated by the four steam turbines, increased by the needs of the electrolyser. As for heating and cooling needs, Table 2 depicts the overall needs. After the heat integration of the plant, there is a net need of 92.3 t/tMeOH of cooling water. The boiler feedwater system circulates 0.92 t/tMeOH of water/steam. The conversion of H2 in the catalytic reactor is of 17 %. The whole process converts 100 % of H2.(95 % if the boiler system is not considered). The conversion rate of CO2 in the catalytic reactor is 22 % (in one pass), while the total conversion in the whole process is 94 %. The total amount of CO2 entering the system is 1.46 t/tMeOH, while the final net amount of CO2 used is 1.28 t/tMeOH, if the electrolyser is powered by renewable sources. Otherwise, when the consumption of electricity of the electrolyser is provided by the European network, there are no net CO2 savings: - 4.70 tCO2/tMeOH, as net CO2 emissions. This means that the process generates more CO2 emissions than the CO2 amount that is utilised as raw material. From now on, the emissions related to the MeOH CDU process consider a renewable source to provide the electricity needed for electrolysis, so that the metric CO2 used is positive (as a design condition). Among the total investment needed (as ISBL) depicted in Figure 5, the electrolyser represents almost 55 % of the total ISBL, EUR 270 million. It is around three times the contributions from the heat exchangers (HEX) and the compression system. The electrolysis size is determined by the stoichiometry of the reaction (Eq. (9)) and the subsequent H2 needs; the HEX is the result of the process integration work and the compression is driven by the reactor need (76 bar). Figure 6 highlights the fact that utilities (electricity, steam and cooling water in this work), and specifically the consumption of electricity, is the main factor responsible for the high production costs. The BCR (Table 2), with a value of 0.29, points out the need to compensate for the high production costs in order for the benefits to be higher than costs. The GM is EUR 167 million/yr which means that the revenues and by-product benefits are larger than the cost of raw materials. This again points out the importance of utility costs. Electrolysis HEX Compression CO2 purification Furnace Turbines Distillation column Pressure vessels Reactor Pumps 47.4 46.8 13.5 7.2 3.3 1.6 1.3 1.0 0.2 147.7 0 20 40 60 80 100 120 140 Total installed cost (M€) Figure 5: Total installed cost (ISBL) breakdown for the MeOH CDU plant. See Table 3 for the comparison between MeOH CDU plant and conventional plants, as a benchmark of the western Europe MeOH industry. Due to the electricity consumption of the electrolyser and its investment, the variable cost for the CDU plant and its capital costs, are higher than those for the conventional plant. The syngas production step in the conventional plant (including oxygen 38PDF Image | evaluation of CO2 utilisation for fuel production
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