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Accelerating the net-zero economy with CO2 hydrogenated formic acid production: Process development and pilot plant demonstration
A process capable of large-scale formic acid (FA) production via CO2 hydrogenation is presented. This study provides the key strategies for use in developing a viable process for continuous operation. Based on the proposed strategies, a pilot-scale process with a capacity of 10 kg/day was constructed. The continuous operability of the process is demonstrated via pilot plant operation for >100 h, achieving a CO2 conversion rate of 82% and producing FA with a high purity of >92 wt %. Techno-economic analysis and life cycle assessment results of the validated simulation model indicate that the proposed process significantly reduces the level of global warming impact by 42% while cutting the production cost by 37%, compared with the conventional process for producing FA. The contents of this study provide a comprehensive manual for developing a viable CO2 utilization solution, showing economic profitability as well as environmental impact reduction.
General technoeconomic analysis for electrochemical coproduction coupling carbon dioxide reduction with organic oxidation
Electrochemical processes coupling carbon dioxide reduction reactions with organic oxidation reactions are promising techniques for producing clean chemicals and utilizing renewable energy. However, assessments of the economics of the coupling technology remain questionable due to diverse product combinations and significant process design variability. Here, we report a technoeconomic analysis of electrochemical carbon dioxide reduction reaction–organic oxidation reaction coproduction via conceptual process design and thereby propose potential economic combinations. We first develop a fully automated process synthesis framework to guide process simulations, which are then employed to predict the levelized costs of chemicals. We then identify the global sensitivity of current density, Faraday efficiency, and overpotential across 295 electrochemical coproduction processes to both understand and predict the levelized costs of chemicals at various technology levels. The analysis highlights the promise that coupling the carbon dioxide reduction reaction with the value-added organic oxidation reaction can secure significant economic feasibility.
Toward economical application of carbon capture and utilization technology with near-zero carbon emission
Carbon capture and utilization technology has been studied for its practical ability to reduce CO2 emissions and enable economical chemical production. The main challenge of this technology is that a large amount of thermal energy must be provided to supply high-purity CO2 and purify the product. Herein, we propose a new concept called reaction swing absorption, which produces synthesis gas (syngas) with net-zero CO2 emission through direct electrochemical CO2 reduction in a newly proposed amine solution, triethylamine. Experimental investigations show high CO2 absorption rates (>84%) of triethylamine from low CO2 concentrated flue gas. In addition, the CO Faradaic efficiency in a triethylamine supplied membrane electrode assembly electrolyzer is approximately 30% (@−200 mA cm−2), twice higher than those in conventional alkanolamine solvents. Based on the experimental results and rigorous process modeling, we reveal that reaction swing absorption produces high pressure syngas at a reasonable cost with negligible CO2 emissions. This system provides a fundamental solution for the CO2 crossover and low system stability of electrochemical CO2 reduction.
