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of the efficiency of the total plant, we will only take these main steps into account and neglect consumption of electricity by pumps and other equipment, which are in gen- eral negligible compared to these more intensive processes. The efficiency of MeOH production E is now given by E = HHVðmethanolÞ EH2O electrolyzer + ECO2 electrolyzer + EBPMED + ECapture (Equation 7) Here, from the assumed efficiency of both water electrolysis (HHV H2 produced per required power input) and CO2 electrolysis (HHV CO produced per required power input), the energy requirements are 816 kJ/mol CO2 and 404 kJ/mol CO2, respec- tively. Furthermore, the BPMED capture unit and air contactor requirements are approximated as 215 kJ/mol CO2 and 13 kJ/mol CO2 as described above, respec- tively. Here, for context, all values are relative to mol of CO2 converted, and conse- quently, mol of MeOH created. The total energy requirement is then 1,448 kJ/mol CO2 converted (see Figure 2), and as a result, the overall energy efficiency of MeOH production is around 50%. Because of the energy lost during the process, attention also needs to be paid to heat management. As water and CO2 electrolysis have the largest contributions to the processes’ energy requirements and the current density in electrolyzers is typi- cally larger than in BPMED, a significant amount of heat will be produced in the elec- trolysis step. For electrolyzer energy efficiencies of 70% there will then be 366 kJ/mol CO2 of heat generated during electrolysis. A typical individual water electrolysis unit of 1.2 MW (300 Nm3/h electrolyzer from Nel) then gives 360 kW of heat per electro- lyzer at ~80C in an alkaline electrolyzer configuration.49 As water electrolyzers have been already scaled to industrial size, proper heat management to maintain the equipment has been developed for individual systems and for Nel’s >50 MW com- bined systems. In addition to the heat produced in the exothermic MeOH synthesis (~250C) and its higher operational temperature, opportunities may be available for using mid- to high-temperature waste heat for heat utilization in other processes. Relative Scale of Each Sub-Process In the design of new energy technologies, it is important to determine early on in research if the proposed solution has the capacity to be scaled to the physical sizes needed to accomplish its envisioned end goal. Similarly, estimating and compre- hending the eventual size of a technology can help streamline designs toward commercialization by removing untenable options. Here, we approximate important physical sizes of the air-to-barrel MeOH synthesis using CO2 electrolyzers from the energy analysis in the previous sections and practical operating conditions for each technology. Specifically, we estimate the required area of fans to capture CO2 from the air, the minimum area of photovoltaics required to power the synthesis process, and the geometric area of catalytic material required to operate a CO2 elec- trolyzer for a 10,000 ton/day plant. First, it is necessary to estimate the typical size of the CO2 capture plant, symbolized by an array of fans in Figure 1. It is first assumed that when using an alkaline KOH cap- ture sorbent, 50% of CO2 (hCap) entering the fan structure can be captured50 and transformed into MeOH from the initial CO2 concentration of 400 ppm in the air. A 10,000 ton/day MeOH plant would then require 27,500 tons of CO2 to pass through the fans each day to capture the 13,750 tons of CO2 required for the plant, assuming no losses in other parts of the process. Using an air density of 1.184 kg/m3 that contains 0.608 g CO2/kg air means that approximately 38.2 km3 of air/day must 1828 Joule 3, 1822–1834, August 21, 2019PDF Image | Pathways to Industrial Scale Fuel from CO2 Electrolysis
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