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Putting CO2 to Use: Creating Value from Emissions Technical analysis demonstration phase (IEA, 2018c). Other production pathways, such as oxidative methane coupling, which involves a reaction between oxygen and methane into higher value chemicals, are in even earlier stages of development. The amount of energy that must be added to convert CO2 varies significantly per type of chemical. In general, producing chemicals from CO2 that are rich in oxygen or contain a so- called carbonate group (CO3) requires much less energy than producing olefins and paraffins (for example methane) that only contain carbon and hydrogen. Furthermore, several conversion routes result in a mix of different substances, meaning that a lot of energy needs to be added to separate the CO2-derived chemical from other substances (Artz et al., 2018). Examples of chemicals with a CO3 group are sodium carbonate (soda ash) and sodium bicarbonate (baking soda) – valuable chemicals for glass manufacture, cleaning agents and detergents – which can be manufactured from CO2 and underground aqueous salt solutions (brine), seawater or salt (NaCl). The chemical process often involves electrolysis to convert the salt-containing substance into a solution of sodium hydroxide. This solution is then reacted with CO2 to produce soda ash or baking soda. Several companies are active in using captured CO2 to produce soda ash and baking soda today. The two largest companies are Carbon Free Chemicals (Skymine® process) and Searles Valley Minerals (Carbon Free Chemicals, 2019; Searles Valley Minerals, 2019). Another example of a company active in this field is Carbon Clean Solutions, which annually captures 60 ktCO2 from a coal-fired power station near Chennai, India. The captured CO2 is used by Indian firm Tuticorin Alkali Chemicals and Fertilizers for soda ash production (Alberici et al., 2017). Polymers are a special group of chemicals that are used in the production of plastics and resins. CO2 can be used in the manufacturing process by replacing part of the fossil-based feedstock (Figure 25). The most mature and widely pursued variant for CO2 use is polycarbonate, which can contain up to 50% CO2 by weight. Unlike the conversion of CO2 to fuels and intermediate chemicals, the use of CO2 in polymer manufacturing does not require significant energy input for the conversion process itself. The energy for conversion is provided by the fossil feedstock – so-called epoxides – in the polymer molecule that is not replaced by the CO2. A number of companies, such as Asahi Kasei Chemicals, Chi Mei Corp and Covestro, are commercially producing polymers using CO2 (Fukuoka et al. 2007; Covestro, 2018). CO2-derived chemicals, such as formic acid, dimethyl ether, formaldehyde and acetic acid, are still in the early stages of development, but may prove promising in the long term (CarbonNext, 2017). Other future opportunities are related to the production of novel materials such as carbon nanofibers (e.g.graphene) using CO2 from air in electrochemical processes (SAM, 2018). However, this pathway is dependent on wider evolution of markets for such materials. The technology is at very early stages of RD&D. The main value proposition of CO2-derived chemicals is the provision of a carbon-containing chemical with lower costs and/or a lower environmental impact than their fossil equivalents. Some chemical feedstocks cannot be decarbonised as the carbon is inherent in providing its structure and properties. Apart from biomass and waste, CO2 is one of the few carbon building blocks that can be used as an alternative raw material for carbon-containing chemicals. PAGE | 49 IEA. All rights reserved.PDF Image | Putting CO2 to Use Creating value from emissions
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