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Energies 2019, 12, 3742 4 of 15 Variable SOE operating pressure SOE steam utilization Steam feed flowrate Sweep-gas feed flowrate Lower Bound 1.1 0.3 0.5 0.1 Upper Bound 78 0.8 15 36 Unit bar - sccm/cm2 sccm/cm2 Table 1. The decision variables and their bounds. Note: The SOE inlet temperature is set at 750 ◦C. The current density is calculated based on the given feed flowrates to reach given steam utilization. 2.2. Methanol Synthesis and Upgrading Methanol production via CO2 hydrogenation is mainly based on two reactions, i.e., methanol synthesis Equation (1) and reverse water gas shift (RWGS) Equation (2) [1,4,19]. 3H2 + CO2 ↔ CH3OH + H2O − ∆H298K = 49.5 kJ/mol (1) H2+ CO2 ↔CO+H2O −∆H298K = −41.2kJ/mol (2) The CO2-to-methanol model is mainly built on the basis of the work of References [4,19]. The commercial catalyst CuO-ZnO-Al2O3 is employed for a feed ratio of H2/CO2 being 3 at 290 ◦C and 78 bar with a recirculation ratio of 5.2, achieving a single-pass CO2-to-methanol conversion of 21% and a crude methanol content of 4.4 vol.%. In line with the capacity of commercial methanol plants, the annual yield of methanol of the proposed system is set as 100 kton with a purity of 99.7 wt%. Assuming annual operation hours of 7200, the CO2 stream fed into the system is around 21 ton/hr. A CO2 capture unit was assumed to be located near the methanol plant supplying carbon dioxide at 2 bar and ambient temperature. We assumed to use captured CO2 because we wanted to fix a cost of carbon dioxide to be used in the economic analysis. Solutions such as the one described in [38] are too dependent on the location of the plant and cannot be generalized. It is mixed with 2.9 ton/h of H2 (17) and then enters the methanol synthesis process. The reactant is pressurized to 78 bar and heated up to 230 ◦C before entering the reactor, which is modeled as an isothermal reactor at 290 ◦C. The resulting gas (22) from the methanol reactor is cooled to 40 ◦C with vapor-liquid separation at 74 bar. The gas stream (33) of unreacted H2 and CO2 is recycled to the reactor after purging around 1.3% of it to avoid the accumulation of inert gases. The liquid stream (24) is relieved to 1.2 bar and fed to the crude methanol flash drum. The residue gas (32), mainly H2 and CO2, is burnt in a waste boiler together with the purge gas to achieve heat recovery. The liquid, the crude methanol of 63 wt% methanol and 37 wt% water, out of the crude methanol flash drum is gas-free. The crude methanol (26) is pressurized to 3 bar and further upgraded in a distillation column (modeled with RadFrac column) to reach a purity of 99.7 wt%. 2.3. Heat Exchanger Network and Steam Turbine Network The performance of the heat exchanger network is estimated by mathematically-formulated heat cascade calculation, described elsewhere [33,39]. The steam turbine network (steam cycle) is employed for heat recovery, which is formulated as described in [40,41]. 3. Methodology The optimal system design is investigated regarding the overall energy efficiency and methanol product cost, as described below.PDF Image | Optimization of CO2-to-Methanol with Solid-Oxide Electrolyzer
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