Process Design and Thermodynamic Evaluation of Flue Gas Conversion into Methanol and Hydrogen Using Wellman–Lord and Amine-Based Capture Technologies

Öz

The rapid advancement of modern civilization has significantly increased global energy demand, leading to higher levels of harmful emissions. This study proposes an integrated system to convert flue gases into valuable products, specifically hydrogen and methanol. The process begins with flue gas desulfurization (FGD) using the Wellman–Lord method (WLM), selected for its high purity output. The recovered sulfur dioxide is processed in an SO2-depolarized electrolyser(SDE) to produce hydrogen and sulfuric acid. Simultaneously, carbon dioxide is captured via amine-based chemical absorption and subsequently hydrogenated to synthesize methanol. The system achieves an overall thermal efficiency of approximately 48%, producing 12 kg/h of methanol and 110 kg/h of sulfuric acid from a 1000 kg/h flue gas stream. These results demonstrate a promising approach for integrating emission reduction with value-added chemical production.

Anahtar Kelimeler

• FlueGas desulfurization
• CO2 Capture
• H2& Methanol Production

Process Design and Thermodynamic Evaluation of Flue Gas Conversion into Methanol and Hydrogen Using Wellman–Lord and Amine-Based Capture Technologies

Öz

ABSTRACT: The rapid advancement of modern civilization has significantly increased global energy demand, leading to higher levels of harmful emissions. This study proposes an integrated system to convert flue gases into valuable products, specifically hydrogen and methanol. The process begins with flue gas desulfurization (FGD) using the Wellman–Lord method (WLM), selected for its high purity output. The recovered sulfur dioxide is processed in an SO2-depolarized electrolyser(SDE) to produce hydrogen and sulfuric acid. Simultaneously, carbon dioxide is captured via amine-based chemical absorption and subsequently hydrogenated to synthesize methanol. The system achieves an overall thermal efficiency of approximately 48%, producing 12 kg/h of methanol and 110 kg/h of sulfuric acid from a 1000 kg/h flue gas stream. These results demonstrate a promising approach for integrating emission reduction with value-added chemical production.

Anahtar Kelimeler

• FlueGas desulfurization
• CO2 Capture
• H2& Methanol Production

Kaynakça

1. [1] M. Igini, “Fossil Fuels Accounted for 82% of Global Energy Mix in 2023 Amid Record Consumption: Report,” Earth.Org, 2024.
2. [2] D. A. Burns et al., “Acid rain and its environmental effects: Recent scientific advances,” Atmospheric Environment, vol. 146, pp. 1–4, 2016, doi: 10.1016/j.atmosenv.2016.10.019.
3. [3] R. Cassia et al., “Climate change and the impact of greenhouse gasses: CO2 and NO, friends and foes of plant oxidative stress,” Frontiers in Plant Science, vol. 9, p. 273, 2018, doi: 10.3389/fpls.2018.00273.
4. [4] P. Madejski et al., “Methods and techniques for CO2 capture: Review of potential solutions and applications in modern energy technologies,” Energies, vol. 15, no. 3, p. 887, 2022, doi: 10.3390/en15030887.
5. [5] M. Songolzadeh et al., “Carbon dioxide separation from flue gases: a technological review emphasizing reduction in greenhouse gas emissions,” The Scientific World Journal, vol. 2014, p. 828131, 2014, doi: 10.1155/2014/828131.
6. [6] P. Gkotsis, E. Peleka, and A. Zouboulis, “Membrane-based technologies for post-combustion CO2 capture from flue gases: Recent progress in commonly employed membrane materials,” Membranes, vol. 13, no. 12, p. 898, 2023, doi: 10.3390/membranes1312898.
7. [7] L. Muzio and G. Often, “Assessment of dry sorbent emission control technologies Part I. Fundamental processes,” Japca, vol. 37, pp. 642–654, 1987, doi: 10.1080/08940630.1987.10466251.
8. [8] R. C. Adams, J. Cotter, and S. Mulligan, Demonstration of Wellman-Lord/Allied Chemical FGD technology: demonstration test first year results. Washington, DC: US Environmental Protection Agency, Industrial Environmental Research Laboratory, 1979.

9. [9] Z. Yuan et al., “Mechanism of flue gas desulfurization with sodium phosphate solution,” Chemical Engineering & Technology, vol. 37, no. 12, pp. 2185–2189, 2014, doi: 10.1002/ceat.201400301.
10. [10] U. Neumann, “The Wellman Lord process,” in Sulphur Dioxide and Nitrogen Oxides in Industrial Waste Gases: Emission, Legislation and Abatement, Springer, 1991, pp. 111–137.
11. [11] F. Shi et al., “An improved Wellman-Lord process for simultaneously recovering SO2 and removing NOX from non-ferrous metal smelting flue gas,” Chemical Engineering Journal, vol. 399, p. 125658, 2020, doi: 10.1016/j.cej.2020.125658.
12. [12] I. Matito-Martos et al., “Potential of CO2 capture from flue gases by physicochemical and biological methods: A comparative study,” Chemical Engineering Journal, vol. 417, p. 128020, 2021, doi: 10.1016/j.cej.2020.128020.
13. [13] E. Moioli, R. Mutschler, and A. Züttel, “Renewable energy storage via CO2 and H2 conversion to methane and methanol: Assessment for small scale applications,” Renewable and Sustainable Energy Reviews, vol. 107, pp. 497–506, 2019, doi: 10.1016/j.rser.2019.03.022.
14. [14] F. Vega et al., “Degradation of amine‐based solvents in CO2 capture process by chemical absorption,” Greenhouse Gases: Science and Technology, vol. 4, no. 6, pp. 707–733, 2014, doi: 10.1002/ghg.1446.
15. [15] M. Martino et al., “Main hydrogen production processes: An overview,” Catalysts, vol. 11, no. 5, p. 547, 2021, doi: 10.3390/catal11050547.
16. [16] M. Amin et al., “Hydrogen production through renewable and non-renewable energy processes and their impact on climate change,” International Journal of Hydrogen Energy, vol. 47, no. 33, pp. 31112–31134, 2022, doi: 10.1016/j.ijhydene.2022.07.172.
17. [17] S. Yosaf, H. Gnaifaid, and A. Mizda, “Thermoeconomic assessments of green hydrogen production via PV&PEM electrolyzer: a case study for Al-Jufra region in Libya,” Journal of Solar Energy and Sustainable Development, vol. 13, no. 1, pp. 57–70, 2024, doi: 10.51646/jsesd.v13i1.172.
18. [18] S. Yosaf, H. Gniaifaid, and A. Abrahem, “Thermodynamic evaluation of hybrid sulfur cycle based on integration system for hydrogen production.”
19. [19] A. J. Bard, Standard Potentials in Aqueous Solution. Routledge, 2017.
20. [20] S. G. Bratsch, “Standard electrode potentials and temperature coefficients in water at 298.15 K,” Journal of Physical and Chemical Reference Data, vol. 18, no. 1, pp. 1–21, 1989, doi: 10.1063/1.555839.
21. [21] A. Lokkiluoto, M. Gasik, and T. Kuikka, “Study of SO2-depolarized water electrolysis,” in Proc. 18th WHEC, Forschungszentrum Jülich GmbH, Essen, 2010, pp. 105–111.
22. [22] J. O’Brien et al., “The electrochemical oxidation of aqueous sulfur dioxide: A critical review of work with respect to the hybrid sulfur cycle,” Electrochimica Acta, vol. 55, pp. 573–591, 2010, doi: 10.1016/j.electacta.2009.09.067.
23. [23] A. Lokkiluoto, Fundamentals of SO2 depolarized water electrolysis and challenges of materials used, 2013.
24. [24] P. Narayana Prasad, Construction and optimization of SO2 depolarized electrolyser, Master’s Thesis, 2023.
25. [25] F. Dalena et al., “Methanol production and applications: an overview,” in Methanol, Elsevier, 2018, pp. 3–28, doi: 10.1016/B978-0-444-63903-5.00001-7.
26. [26] B. Kanjilal, A. Masoumi, and I. Noshadi, “Photocatalytic process for syngas production,” in Advances in Synthesis Gas: Methods, Technologies and Applications, Elsevier, 2023, pp. 261–290.
27. [27] A. G. Konstandopoulos et al., “Solar fuels and industrial solar chemistry,” in Concentrating Solar Power Technology, Elsevier, 2021, pp. 677–724.
28. [28] R. Guil-López et al., “Methanol synthesis from CO2: a review of the latest developments in heterogeneous catalysis,” Materials, vol. 12, no. 23, p. 3902, 2019, doi: 10.3390/ma12233902.
29. [29] M. A. Arellano-Trevino et al., “Bimetallic catalysts for CO2 capture and hydrogenation at simulated flue gas conditions,” Chemical Engineering Journal, vol. 375, p. 121953, 2019, doi: 10.1016/j.cej.2019.121953.