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Figure 4. Critical Scales of Each Sub-Process Important solar photovoltaic, direct air capture, and CO2 electrolyzer catalyst areas (in orange) needed to build a 10,000 ton/day air-to-barrel methanol plant using ambient molecules as an input. The CO2 electrolyzer areas assume currently achievable current densities of 0.4 A cm2 for CO at 100% faradic efficiency. These areas are compared to the world’s largest or largest planned installations for each respective technology to provide context to the orders of magnitudes needed for centralized solar fuel production. The range of current reported CO2 electrolyzer areas is also reported. magnitude to the solar land area of the Pavagada Solar Park.57 The minimum area of CO2 capture units, however, is three orders of magnitude larger than the largest Cli- meworks plant installed in Zurich.58 Finally, and with the largest disparity, the largest CO2 reduction catalyst areas to date23,59 are only <0.04 m2 versus the estimated 0.175 km2 catalyst areas estimated for these plants. While this difference itself is phenomenal, we can also see that such a MeOH plant also requires substantially larger catalyst areas for the CO2 electrolyzer than even the largest water electrolyzer (Nel, Norsk Hydro),49,60 chlori-alkali plant (Dow-Mitsui),61 and proton-exchange- membrane (PEM) electrolyzer units,62 which are predicted as 37,500 m2, 13,500 m2, and 167 m2, respectively (see Supplemental Information for details). In light of this current gap between the needed catalyst size and existing technology, tough discussions need to take place regarding whether some of the proposed technological configurations or materials for electrochemical CO2 reduction in the literature are capable of scaling to the sizes needed to impact global capacities. Furthermore, this result highlights the need for additional efforts to be placed on developing scaled-up and scaled-out CO2 electrolyzer systems in parallel to devel- oping better catalysts. Finally, a common theme here for several of the integrated components is the continuous discussion around planar areas of materials and systems, rather than volumes. This differs from thermally driven processes that have traditionally scaled closer to the volume of components and subsequently benefitted from economies of scale, leading to extremely large plants. In the analysis presented here, we see that the need for renewably driven processes to scale by increasing cross-sectional area (e.g., solar panels, capture areas, and electrolyzer catalysts) may force us to change the current way in which we produce chemicals, which is via mega-plants. Since economies of scale are comparatively less beneficial for electrically driven chemical processes, and the proposed areas needed for a 10,000 ton/day plant are extremely large, decentralized or smaller installations may then be more desired practically and economically. Further discussions are then needed to deter- mine what level of centralization versus decentralization will be optimal for future Joule 3, 1822–1834, August 21, 2019 1831PDF Image | Pathways to Industrial Scale Fuel from CO2 Electrolysis
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