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Title: A Carbon Dioxide Refinery: The Core of a Sustainable Carbon-based Circular Economy

Journal Article · · Highlights of Sustainability

The atmospheric carbon dioxide (CO2) accumulation (2–2.5 ppmv/year) is the result of the enormous gap between its emissions (37 Gton/year) and its capture, storage, and utilization (<500 Mton/year). Climate has been dramatically affected due to the failure of natural sinks, in working effectively. To address this Gton-scale gap, numerous uses and applications are needed particularly, those consuming vast volumes of this compound and/or rendering longevous products or long lifecycle services. Thus, carbon utilization (CU) can be seen as the step to close the carbon cycle. Among CU, R&D on CO2 chemical conversion has proposed a variety of processes, with different degrees of developmental maturity. These chemical process technologies could be efficiently and effectively integrated into refineries to upgrade emitted CO2. A technology pipeline consisting of a database of these processes and the technology market status should be defined based on published scientific results and patents. Then, an innovative top-down methodology is proposed to eco-design configurations of that refinery, to warrant a sustainable carbon cycle (in terms of energy, environment, and economy) and to change the ways of producing fuels, chemicals, and materials. Additionally, the proposed methodology could be used to identify research and development gaps and needs, for orienting science and technology investments and measures. Hopefully, sustainable CO2 refineries will be implemented to close the carbon cycle of a circular C-based economy and underpin a decarbonized chemical industry.

Research Organization:
Idaho National Laboratory (INL), Idaho Falls, ID (United States)
Sponsoring Organization:
USDOE Laboratory Directed Research and Development (LDRD) Program
Grant/Contract Number:
AC07-05ID14517
OSTI ID:
2403044
Report Number(s):
INL/JOU-23-73094-Rev000
Journal Information:
Highlights of Sustainability, Journal Name: Highlights of Sustainability Journal Issue: 2 Vol. 3; ISSN 2696-628X
Publisher:
Highlights of ScienceCopyright Statement
Country of Publication:
United States
Language:
English

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  • Galvita, Vladimir V.; Poelman, Hilde; Bliznuk, Vitaliy
  • Industrial & Engineering Chemistry Research, Vol. 52, Issue 25, p. 8416-8426 https://doi.org/10.1021/ie4003574
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The Structure of Urea-Formaldehyde Resins1 journal September 1946
Electrocatalytic Conversion of Carbon Dioxide to Methane and Methanol on Transition Metal Surfaces journal August 2014
Enhanced Electrochemical Methanation of Carbon Dioxide with a Dispersible Nanoscale Copper Catalyst journal September 2014
Turning on the Protonation-First Pathway for Electrocatalytic CO 2 Reduction by Manganese Bipyridyl Tricarbonyl Complexes journal February 2017
Integrative CO 2 Capture and Hydrogenation to Methanol with Reusable Catalyst and Amine: Toward a Carbon Neutral Methanol Economy journal January 2018
Metal-Catalyzed Dimethyl Carbonate Synthesis from Carbon Dioxide and Acetals journal May 1999
Microwave-Specific Enhancement of the Carbon–Carbon Dioxide (Boudouard) Reaction journal November 2013
Preparation of High-Molecular-Weight Aliphatic Polycarbonates by Condensation Polymerization of Diols and Dimethyl Carbonate journal April 2013
Silica accelerates the selective hydrogenation of CO2 to methanol on cobalt catalysts journal February 2020
Synergistic promotions between CO2 capture and in-situ conversion on Ni-CaO composite catalyst journal February 2023
Residual fossil CO2 emissions in 1.5–2 °C pathways journal June 2018
Organic bases catalyze the synthesis of urea from ammonium salts derived from recovered environmental ammonia journal February 2020
The renaissance of the Sabatier reaction and its applications on Earth and in space journal March 2019
Electrocatalytic reduction of CO2 to ethylene and ethanol through hydrogen-assisted C–C coupling over fluorine-modified copper journal April 2020
A novel non-phosgene polycarbonate production process using by-product CO 2 as starting material journal January 2003
Electrochemical activation of CO2 in ionic liquid (BMIMBF4): synthesis of organic carbonates under mild conditions journal January 2008
The teraton challenge. A review of fixation and transformation of carbon dioxide journal January 2010
Carbon dioxide (CO 2 ) as sustainable feedstock for polyurethane production journal January 2014
Insights into the electrocatalytic reduction of CO 2 on metallic silver surfaces journal January 2014
A review of mineral carbonation technologies to sequester CO 2 journal January 2014
Methanol synthesis via CO2hydrogenation over a Au/ZnO catalyst: an isotope labelling study on the role of CO in the reaction process journal January 2016
Carbon dioxide reduction on Ir(111): stable hydrocarbon surface species at near-ambient pressure journal January 2016
Low carbon fuels and commodity chemicals from waste gases – systematic approach to understand energy metabolism in a model acetogen journal January 2016
Synthesis of high-molecular-weight aliphatic polycarbonates by organo-catalysis journal January 2016
Catalytic hydrogenation of CO 2 to methanol in a Lewis pair functionalized MOF journal January 2016
CO 2 conversion by reverse water gas shift catalysis: comparison of catalysts, mechanisms and their consequences for CO 2 conversion to liquid fuels journal January 2016
Highly productive CO 2 hydrogenation to methanol – a tandem catalytic approach via amide intermediates journal January 2017
Electrochemical CO 2 reduction on Au surfaces: mechanistic aspects regarding the formation of major and minor products journal January 2017
Unravelling the mechanisms of CO2 hydrogenation to methanol on Cu-based catalysts using first-principles multiscale modelling and experiments journal January 2017
Electrochemical production of syngas from CO 2 captured in switchable polarity solvents journal January 2018
Modeling gas-diffusion electrodes for CO 2 reduction journal January 2018
Bimetallic catalysts for green methanol production via CO 2 and renewable hydrogen: a mini-review and prospects journal January 2018
CO 2 reduction on gas-diffusion electrodes and why catalytic performance must be assessed at commercially-relevant conditions journal January 2019
Parametric sensitivity in the Sabatier reaction over Ru/Al 2 O 3 – theoretical determination of the minimal requirements for reactor activation journal January 2019
Highly selective CO removal by sorption enhanced Boudouard reaction for hydrogen production journal January 2019
An alkaline polymer electrolyte CO 2 electrolyzer operated with pure water journal January 2019
Electrocatalytic reduction of carbon dioxide: opportunities with heterogeneous molecular catalysts journal January 2020
A self-recovering robust electrode for highly efficient CO2 electrolysis in symmetrical solid oxide electrolysis cells journal January 2019
Syngas production from electrocatalytic CO 2 reduction with high energetic efficiency and current density journal January 2019
Engineering the atomic arrangement of bimetallic catalysts for electrochemical CO2 reduction journal January 2021
The carbon footprint of the carbon feedstock CO 2 journal January 2020
CO2 green technologies in CO2 capture and direct utilization processes: methanation, reverse water-gas shift, and dry reforming of methane journal January 2020
Towards accelerated durability testing protocols for CO 2 electrolysis journal January 2020
Electrografting amines onto silver nanoparticle-modified electrodes for electroreduction of CO2 at low overpotential journal January 2021
Atomically dispersed single Ni site catalysts for high-efficiency CO2 electroreduction at industrial-level current densities journal January 2022
Direct carbonate electrolysis into pure syngas journal January 2023
Ni/Co in and on CeO2: a comparative study on the dry reforming reaction journal January 2023
Recent developments in carbon dioxide utilization under mild conditions journal January 2010
Syngas production via high-temperature steam/CO2 co-electrolysis: an economic assessment journal January 2010
Organo-catalyzed synthesis of aliphatic polycarbonates in solvent-free conditions journal January 2012
Boosted CO2 reaction with methanol to yield dimethyl carbonate over Mg–Al hydrotalcite-silica lyogels journal January 2013
Synthesis of Carbamates from Amines and Dialkyl Carbonates: Influence of Leaving and Entering Groups journal May 2010
Current progress on zeolite membrane reactor for CO2 hydrogenation
  • Makertiharta, I. G. B. N.; Dharmawijaya, P. T.; Wenten, I. G.
  • INTERNATIONAL CONFERENCE ON ENGINEERING, SCIENCE AND NANOTECHNOLOGY 2016 (ICESNANO 2016), AIP Conference Proceedings https://doi.org/10.1063/1.4968389
conference January 2017
Infrastructure to enable deployment of carbon capture, utilization, and storage in the United States journal September 2018
MgAl 2 O 4 with CaO in supported Ni and Ni–Co catalysts – impact on CO 2 reforming of CH 4 journal August 2023
The Chemical Structure of UF Resins journal January 1986
Recent Advances in Urea–Formaldehyde Resins: Converting Crystalline Thermosetting Polymers Back to Amorphous Ones journal December 2021
Harnessing renewable energy with CO 2 for the chemical value chain: challenges and opportunities for catalysis
  • Klankermayer, Jürgen; Leitner, Walter
  • Philosophical Transactions of the Royal Society A: Mathematical, Physical and Engineering Sciences, Vol. 374, Issue 2061 https://doi.org/10.1098/rsta.2015.0315
journal February 2016
Applications of Urea‐Formaldehyde Resin Glues journal June 1941
Inherent CO2 Capture Using Chemical Looping Combustion in a Natural Gas Fired Power Cycle journal April 2004
Syngas Production via High-Temperature Coelectrolysis of Steam and Carbon Dioxide journal November 2008
Low Overpotential Electroreduction of CO2 on Porous SnO2/ZnO Catalysts journal June 2023
Thermodynamic Analysis of the Chemical Heat Pipe as a Closed Cycle Gas Turbine
  • Osterle, Fletcher
  • Volume 3: Coal, Biomass and Alternative Fuels; Combustion and Fuels; Oil and Gas Applications; Cycle Innovations https://doi.org/10.1115/88-GT-122
conference June 1988
A highly selective and stable ZnO-ZrO 2 solid solution catalyst for CO 2 hydrogenation to methanol journal October 2017
Stabilization Wedges: Solving the Climate Problem for the Next 50 Years with Current Technologies journal August 2004
CO 2 electroreduction to ethylene via hydroxide-mediated copper catalysis at an abrupt interface journal May 2018
What would it take for renewably powered electrosynthesis to displace petrochemical processes? journal April 2019
CO 2 electrolysis to multicarbon products at activities greater than 1 A cm −2 journal February 2020
Nickel Supported on Alkaline Earth Metal–Doped γ-Al2O3–La2O3 as Catalysts for Dry Reforming of Methane journal February 2020
Urea–Melamine Formaldehyde Resin for the Manufacture of Water-Resistant Plywood journal December 2022
Boundaries of High-Temperature Co-Electrolysis Towards Direct CO2-Electrolysis journal July 2021
Review—Electrochemical CO 2 Reduction for CO Production: Comparison of Low- and High-Temperature Electrolysis Technologies journal January 2020
Advancements in Development of Chemical-Looping Combustion: A Review journal January 2009
The production of renewable energy in the form of methane using electrolytic hydrogen generation journal August 2014
Methanation of CO2 - storage of renewable energy in a gas distribution system journal December 2014
Comparative Study of the Storage Stability between a Melamine-Urea-Formaldehyde and a Urea-Formaldehyde Resin journal March 2012
Formaldehyde Liberation and Cure Behavior of Urea-Formaldehyde Resins journal January 1990
Modeling and Testing of a Milli-Structured Reactor for Carbon Dioxide Methanation journal August 2019
Low Mole Ratio Urea–Melamine–Formaldehyde Resins Entailing Increased Methylene-Ether Group Contents and Their Formaldehyde Emission Potentials of Wood Composite Boards journal July 2013
A Comparison of Different Approaches to the Conversion of Carbon Dioxide into Useful Products: Part I journal April 2021
Thermally Stable Nickel-Molybdenum Alloy Catalysts Supported on Zirconia for High Temperature Methanation journal January 1982
Gaseous Carbon Waste Streams Utilization: Status and Research Needs book January 2019
Negative Emissions Technologies and Reliable Sequestration book March 2019
Mass-Recirculating Systems in CO2 Capture Technologies: A Review journal January 2010
The Electrochemical Conversion of CO2 into Methanol with KHCO3 Electrolyte Using Membrane Electrode Assembly (MEA) journal October 2023
Process Advantages of Direct CO2 to Methanol Synthesis journal September 2018
Progress in the CO2 Capture Technologies for Fluid Catalytic Cracking (FCC) Units—A Review journal April 2020
Economics of CO2 Utilization: A Critical Analysis journal September 2020
Catalytic Conversion of Carbon Dioxide to Methanol: Current Status and Future Perspective journal February 2021
Low-Temperature Electrocatalytic Conversion of CO2 to Liquid Fuels: Effect of the Cu Particle Size journal August 2018
Power-to-Green Methanol via CO2 Hydrogenation—A Concept Study including Oxyfuel Fluidized Bed Combustion of Biomass journal July 2021
Metals Production, CO2 Mineralization and LCA journal March 2020
Eco-Friendly, High-Density Fiberboards Bonded with Urea-Formaldehyde and Ammonium Lignosulfonate journal January 2021
Smart Designs of Anti-Coking and Anti-Sintering Ni-Based Catalysts for Dry Reforming of Methane: A Recent Review journal December 2020
Anion effect controlling the selectivity in the zinc-catalysed copolymerisation of CO2 and cyclohexene oxide journal January 2015
Effects of Addition Ammonia Modified Urea-Melamine-Formaldehyde Resin on the Adhesions and Formaldehyde Emission in Plywood journal June 2010
Study on CO2 Hydrogenation to Ethylene with Iron-Based Catalyst journal September 2013
Sabatier Carbon Dioxide Reduction System for Long-Duration Manned Space Application conference July 1991
Evolution, Fields of Research, and Future of Chemical-Looping Combustion (CLC) process: A Review journal December 2014
Hydrolytic Stability of Cured Urea-Melamine-Formaldehyde Resins Depending on Hydrolysis Conditions and Hardener Types journal September 2015