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The final balance of CO2 emissions is positive for the FA CDU plant when compared to the conventional plant, with electrolysis and steam using zero CO2 emissions sources (see the environmental metrics in Table 6). Table 8 compares the CDU plant and the methyl formate hydrolysis process to produce FA, including generation of CO. Note that the emissions of the conventional plant do not take into account either renewable electricity or renewable steam; reference values from bibliography are considered for electricity and steam consumptions [114], [146], and the emission factors used are those from [113] and [43]. This leads into an optimistic comparison for the CDU plant, towards the conventional plant. Whereas the CDU plant consumes less steam than the conventional plant and the final balance of CO2 emissions shows a clear advantage for the CDU plant (mainly because of the use of zero CO2 emissions sources for electricity and steam production), the production costs are notably higher than for the conventional plant. This is mainly due to the contribution of consumables (mainly catalysts), the higher consumption of electricity, due to electrolyser needs, and steam, due to the process heating needs. An emission change (reduction) of 92 % exists when producing FA with a CDU process, corresponding to 2 tCO2/tFA not-emitted. The production of 12 kt FA/yr with a CDU plant saves almost 5 kt/yr of heavy fuel oil. Electrolysis Compression Separation processes Reactor HEX CO2 purification Pumps 0 731 446 363 212 138 2036 2,000 2909 3,000 1,000 Total installed cost (k€) Figure 15: Total installed cost (ISBL) breakdown for the FA CDU plant. 7.4 3.1 0.2 0.1 0.4 0.2 6.5 Salary and overheads Maintenance Interest Utilities Consumables Raw materials FA revenue By-product revenue 8.2 -8 -3 2 7 Operating costs (M€/yr) Figure 16: Operating costs breakdown for the FA CDU plant. FCP in grey bars, VCP in grey striped bars and FA and oxygen revenues in orange striped bars. Overall, four bottlenecks can be identified in the scale-up of the CDU process: high cost and large electricity consumption of H2 production; the high cost of the new catalysts and/or solvents; the mandatory coupling with renewables; and the uncertainty linked to the layout of the process (due to low TRL. This last may lead to under or over estimations of the KPIs in the current analysis. 55PDF Image | evaluation of CO2 utilisation for fuel production
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