Bringing value to the chemical industry from capture, storage and use of CO2: A dynamic LCA of formic acid production

Mechanochemical Synthesis of High-Entropy MOF-74 with Multiple Active Sites for CO2 Adsorption and Synergistic Conversion

Compared with monometallic metal-organic frameworks (MOFs), the synergistic effect of multiple metals significantly enhances the catalytic performance of the CO2 cycloesterification reaction, leading to improved CO2 adsorption and catalytic conversion capabilities. To investigate this concept, a high-entropy MOF-74 (HE-MOF-74) with a uniform distribution of five distinct metal ions (Zn2+, Mg2+, Ni2+, Co2+, and Cu2+) was successfully synthesized using a straightforward mechanical ball milling technique and comprehensively characterized (including structural, morphological, and physicochemical properties). The results reveal that HE-MOF-74 exhibits significantly increased specific surface area and CO2 adsorption capacity compared with those of monometallic MOF-74. The presence of multiple unsaturated metal centers as Lewis acid sites, oxygen atoms linking the metals, and ligand-based hydroxyl groups serving as base sites enable efficient immobilization of CO2 into cyclic carbonate. This study introduces a novel synthetic approach for the green and efficient production of HE-MOF-74 and proposes a new application for CO2 utilization.

Recent advances in CO2 reduction with renewable reductants under hydrothermal conditions: towards efficient and net carbon benefit CO2 conversion

The ever-growing atmospheric CO2 concentration threatening the environmental sustainability of humankind makes the reduction of CO2 to chemicals or fuels an ideal solution. Two priorities are anticipated for the conversion technology, high efficiency and net carbon benefit, to ensure the mitigation of the CO2 problem both promptly and sustainably. Until now, catalytic hydrogenation or solar/electro-chemical CO2 conversion have achieved CO2 reduction promisingly while, to some extent, compromising to fulfill the two rules, and thus alternative approaches for CO2 reduction are necessary. Natural geochemical processes as abiotic CO2 reductions give hints for efficient CO2 reduction by building hydrothermal reaction systems, and this type of reaction atmosphere provides room for introducing renewable substances as reductants, which offers the possibility to achieve CO2 reduction with net carbon benefit. While the progress in CO2 reduction has been abundantly summarized, reviews on hydrothermal CO2 reduction are relatively scarce and, more importantly, few have focused on CO2 reduction with renewable reductants with the consideration of both scale of efficiency and sustainability. This review provides a fundamental and critical review of metal, biomass and polymer waste as reducing agents for hydrothermal CO2 reduction. Various products including formic acid, methanol, methane and multi-carbon chemicals can be formed, and effects of operational parameters such as temperature, batch holding time, pH value and water filing as well as detailed reaction mechanisms are illustrated. Particularly, the critical roles of high temperature and pressure water as reaction promotor and catalyst in hydrothermal CO2 conversion are discussed at the mechanistic level. More importantly, this review compares hydrothermal CO2 reduction with other methods such as catalytic hydrogenation and photo/electrocatalysis, evaluating their efficiency and potential for net carbon benefit. The aim of this review is to promote the understanding of CO2 activation under a hydrothermal environment and provide insights into the efficient and sustainable strategy of hydrothermal CO2 conversion for future fundamental research and industrial applications.

Recent advances in energy efficiency optimization methods for plasma CO2 conversion

Efforts to develop efficient methods for converting carbon dioxide (CO2) have drawn mounting interest due to incremental concerns over carbon emissions. Non-thermal plasma (NTP) technology has shown promise in this regard by producing numerous reactive substances at relatively low temperatures. However, an analysis of relevant literature reveals an underwhelming level of overall energy efficiency for this technology and an insufficient level of attention being paid to it. It is crucial to put forward more effective energy-saving schemes based on a comprehensive analysis of past research results to promote sustained development. This review highlights the latest advances in pertinent energy efficiency optimization studies and outlines state-of-the-art methods. In terms of energy efficiency optimization for plasma CO2 conversion, a comparison is made among different research results in four aspects as follows. Specifically, this study analyzes reactor structure optimization in terms of discharge characteristic, flow field, and plasma contact area; discusses pathways of heat transfer optimization to suppress the competing reaction; and explores catalyst optimization in terms of active sites, calcination temperature, and product selectivity; examines the potential of utilizing solar energy for clean energy applications. The analysis of energy efficiency data indicates an overall improvement when the aforementioned optimization measures are applied, which is essential to validate the effectiveness of each method. Finally, this paper discusses the potential difficulties and future research areas of NTP technology. Urgent further research is imperative on energy efficiency optimization methods for potential large-scale industrial applications in the future.

The Relevance of Life Cycle Assessment Tools in the Development of Emerging Decarbonization Technologies

The development of emerging decarbonization technologies requires advanced tools for decision-making that incorporate the environmental perspective from the early design. Today, Life Cycle Assessment (LCA) is the preferred tool to promote sustainability in the technology development, identifying environmental challenges and opportunities and defining the final implementation pathways. So far, most environmental studies related to decarbonization emerging solutions are still limited to midpoint metrics, mainly the carbon footprint, with global sustainability implications being relatively unexplored. In this sense, the Planetary Boundaries (PBs) have been recently proposed to identify the distance to the ideal reference state. Hence, PB-LCA methodology can be currently applied to transform the resource use and emissions to changes in the values of PB control variables. This study shows a complete picture of the LCA's role in developing emerging technologies. For this purpose, a case study based on the electrochemical conversion of CO2 to formic acid is used to show the possibilities of LCA approaches highlighting the potential pitfalls when going beyond greenhouse gas emission reduction and obtaining the absolute sustainability level in terms of four PBs.

Upcycling air pollutants to fuels and chemicals via electrochemical reduction technology

The intensification of fossil fuel usage results in significant air pollution levels. Efforts have been put into developing efficient technologies capable of converting air pollution into valuable products, including fuels and valuable chemicals (e.g., CO₂ to hydrocarbon and syngas and NO_x to ammonia). Among the strategic efforts to mitigate the excessive concentration of CO₂ and NO_x pollutants in the atmosphere, the electrochemical reduction technology of CO₂ (CO₂RR) and NO_x (NO_xRR) emerges as one of the most promising approaches. It is even more attractive if CO₂RR and NO_xRR are paired with renewables to store intermittent electricity in the form of chemical feedstocks. This review provides an overview of the electrochemical reduction process to convert CO₂ to C₁ and/or C₂₊ chemicals and NO_x to ammonia (NH₃) with a focus on electrocatalysts, electrolytes, electrolyzer, and catalytic reactor designs toward highly selective electrochemical conversion of the desired products. While the attempts in these aspects are enormous, economic consideration and environmental feasibility for actual implementation are not comprehensively provided. We discuss CO₂RR and NO_xRR from the life cycle and techno-economic analyses to perceive the feasibility of the current achievements. The remaining challenges associated with the industrial implementation of electrochemical CO₂ and NO_x reduction are additionally provided.

Economic and Environmental Performance of an Integrated CO2 Refinery

The consequences of global warming call for a shift to circular manufacturing practices. In this context, carbon capture and utilization (CCU) has become a promising alternative toward a low-emitting chemical sector. This study addresses for the first time the design of an integrated CO₂ refinery and compares it against the business-as-usual (BAU) counterpart. The refinery, which utilizes atmospheric CO₂, comprises three synthesis steps and coproduces liquefied petroleum gas, olefins, aromatics, and methanol using technologies that were so far studied decoupled from each other, hence omitting their potential synergies. Our integrated assessment also considers two residual gas utilization (RGU) designs to enhance the refinery's efficiency. Our analysis shows that a centralized cluster with an Allam cycle for RGU can drastically reduce the global warming impact relative to the BAU (by ≈135%) while simultaneously improving impacts on human health, ecosystems, and resources, thereby avoiding burden-shifting toward human health previously observed in some CCU routes. These benefits emerge from (i) recycling CO₂ from the cycle, amounting to 11.2% of the total feedstock, thus requiring less capture capacity, and (ii) reducing the electricity use while increasing heating as a trade-off. The performance of the integrated refinery depends on the national grid, while its high cost relative to the BAU is due to the use of expensive electrolytic H₂ and atmospheric CO₂ feedstock. Overall, our work highlights the importance of integrating CCU technologies within chemical clusters to improve their economic and environmental performance further.

Trade-offs between Sustainable Development Goals in carbon capture and utilisation

Carbon capture and utilisation (CCU) provides an appealing framework to turn carbon emissions into valuable fuels and chemicals. However, given the vast energy required to activate the CO₂ molecule, CCU may have implications on sustainable development that are still poorly understood due to the narrow scope of current carbon footprint-oriented assessments lacking absolute sustainability thresholds. To bridge this gap, we developed a power-chemicals nexus model to look into the future and understand how we could produce 22 net-zero bulk chemicals of crucial importance in a sustainable manner by integrating fossil, CCU routes and power technologies, often assessed separately. We evaluated the environmental performance of these technologies in terms of their contribution to 5 Sustainable Development Goals (SDGs), using 16 life cycle assessment metrics and 9 planetary boundaries (PB) to quantify and interpret the impact values. We found that fossil chemicals could hamper the attainment of SDG 3 on good health and well-being and SDG 13 on climate change. CCU could help meet SDG 13 but would damage other SDGs due to burden-shifting to human health, water scarcity, and minerals and metals depletion impacts. The collateral damage could be mitigated by judiciously combining fossil and CCU routes with carbon-negative power sources guided by optimisation models incorporating SDGs-based performance criteria explicitly. Our work highlights the importance of embracing the SDGs in technology development to sensibly support the low-carbon energy and chemicals transition.

To Adopt CCU Technology or Not? An Evolutionary Game between Local Governments and Coal-Fired Power Plants

Carbon dioxide capture and utilization (CCU) technology is a significant means by which China can achieve its ambitious carbon neutrality goal. It is necessary to explore the behavioral strategies of relevant companies in adopting CCU technology. In this paper, an evolutionary game model is established in order to analyze the interaction process and evolution direction of local governments and coal-fired power plants. We develop a replicator dynamic system and analyze the stability of the system under different conditions. Based on numerical simulation, we analyze the impact of key parameters on the strategies of stakeholders. The simulation results show that the unit prices of hydrogen and carbon dioxide derivatives have the most significant impact: when the unit price of hydrogen decreases to 15.9 RMB/kg or the unit price of carbon dioxide derivatives increases to 3.4 RMB/kg, the evolutionary stabilization strategy of the system changes and power plants shift to adopt CCU technology. The results of this paper suggest that local governments should provide relevant support policies and incentives for CCU technology deployment, as well as focusing on the synergistic development of CCU technology and renewable energy hydrogen production technology.

Facile One-Pot Synthesis of Zn/Mg-MOF-74 with Unsaturated Coordination Metal Centers for Efficient CO2 Adsorption and Conversion to Cyclic Carbonates

Bimetallic metal-organic frameworks (MOFs) containing two different inorganic metal nodes exhibited enhanced properties in CO₂ adsorption and catalytic conversion compared with the corresponding monometallic MOFs. In this work, the novel bimetallic Zn/Mg-MOF-74 with different ratios of Zn/Mg was synthesized successfully by a facile one-pot method. Powder X-ray diffraction, Fourier transform infrared, X-ray photoelectron spectroscopy, scanning electron microscopy/transmission electron microscopy, N₂/CO₂ adsorption/desorption, and CO₂/NH₃-temperature-programmed desorption techniques thoroughly characterized the structure, morphology, and physicochemical properties of Zn/Mg-MOF-74. Besides the excellent CO₂ adsorption capacity (128.3 cm³/g at 273 K and 1 bar), Zn_0.75Mg_0.25-MOF-74 also showed efficient catalytic activity for the cycloaddition reaction of CO₂ and epoxides to cyclic carbonates with outstanding yield and selectivity all over 99% under solvent-free and mild conditions (60 °C, 0.8 MPa), outperforming the mechanical combination of Zn-MOF-74 and Mg-MOF-74 with the same metal contents, indicating the synergistic effect of two adjacent metals in bimetallic MOF-74. In addition, the Zn_0.75Mg_0.25-MOF-74 catalyst could be recycled for at least five runs and possess good versatility to various substrates. Finally, a feasible mechanism of the catalytic reaction was proposed. Thanks to the high surface area, affinity toward CO₂, and accessibility of multiple active sites of the unsaturated metal centers as active Lewis acid sites and O atoms from Zn-O and Mg-O as Lewis basic sites, efficient chemical fixation of CO₂ to cyclic carbonates was obtained over the Zn_0.75Mg_0.25-MOF-74 catalyst. The present facile synthesis and application of a robust bimetallic MOF catalyst offered a competitive avenue for the integration of CO₂ adsorption and CO₂ catalytic conversion.

Stepping Stones in CO2 Utilization: Optimizing the Formate to Oxalate Coupling Reaction Using Response Surface Modeling

One of the crucial steps for the conversion of CO₂ into polymers is the catalytic formate to oxalate coupling reaction (FOCR). Formate can be obtained from the (electro)catalytic reduction of CO₂, while oxalate can be further processed toward building blocks for modern plastics. In its 175 year history, multiple parameters for the FOCR have been suggested to be of importance. Yet, no comprehensive understanding considering all those parameters is available. Hence, we aim to assess the relative impact of all those parameters and deduce the optimal reaction conditions for the FOCR. We follow a systematic two-stage approach in which we first evaluate the most suitable categorical variables of catalyst, potential poisons, and reaction atmospheres. In the second stage, we evaluate the impact of the continuous variables temperature, reaction time, catalyst loading, and active gas removal within previously proposed ranges, using a response surface modeling methodology. We found KOH to be the most suitable catalyst, and it allows yields of up to 93%. Water was found to be the strongest poison, and its efficient removal increased oxalate yields by 35%. The most promising reaction atmosphere is hydrogen, with the added benefit of being equal to the gas produced in the reaction. The temperature has the highest impact on the reaction, followed by reaction time and purge rates. We found no significant impact of catalyst loading on the reaction within the ranges reported previously. This research provides a clear and concise multiparameter optimization of the FOCR and provides insight into the reaction cascade involving the formation and decomposition of oxalates from formate.

Process modeling, techno-economic assessment, and life cycle assessment of the electrochemical reduction of CO2: a review

The electrochemical reduction of CO2 has emerged as a promising alternative to traditional fossil-based technologies for the synthesis of chemicals. Its industrial implementation could lead to a reduction in the carbon footprint of chemicals and the mitigation of climate change impacts caused by hard-to-decarbonize industrial applications, among other benefits. However, the current low technology readiness levels of such emerging technologies make it hard to predict their performance at industrial scales. During the past few years, researchers have developed diverse techniques to model and assess the electrochemical reduction of CO2 toward its industrial implementation. The aim of this literature review is to provide a comprehensive overview of techno-economic and life cycle assessment methods and pave the way for future assessment approaches. First, we identify which modeling approaches have been conducted to extend analysis to the production scale. Next, we explore the metrics used to evaluate such systems, regarding technical, environmental, and economic aspects. Finally, we assess the challenges and research opportunities for the industrial implementation of CO2 reduction via electrolysis.

Process modelling and life cycle assessment coupled with experimental work to shape the future sustainable production of chemicals and fuels

Meeting the sustainable development goals and carbon neutrality targets requires transitioning to cleaner products, which poses significant challenges to the future chemical industry. Identifying alternative pathways to cover the growing demand for chemicals and fuels in a more sustainable manner calls for close collaborative programs between experimental and computational groups as well as new tools to support these joint endeavours. In this broad context, we here review the role of process systems engineering tools in assessing and optimising alternative chemical production patterns based on renewable resources, including renewable carbon and energy. The focus is on the use of process modelling and optimisation combined with life cycle assessment methodologies and network analysis to underpin experiments and generate insight into how the chemical industry could optimally deliver chemicals and fuels with a lower environmental footprint. We identify the main gaps in the literature and provide directions for future work, highlighting the role of PSE concepts and tools in guiding the future transition and complementing experimental studies more effectively.

Monomers from CO2 : Superbases as Catalysts for Formate-to-Oxalate Coupling

An interesting contribution to solving the climate crisis involves the use of CO₂ as a feedstock for monomers to produce sustainable plastics. In the European Horizon 2020 project "OCEAN" a continuous multistep process from CO₂ to oxalic acid and derivatives is developed, starting with the electrochemical reduction of CO₂ to potassium formate. The subsequent formate-to-oxalate coupling is a reaction that has been studied and commercially used for over 150 years. With the introduction of superbases as catalysts under moisture-free conditions unprecedented improvements were shown for the formate coupling reaction. With isotopic labelling experiments the presence of carbonite as an intermediate was proven during the reaction, and with a unique operando set-up the kinetics were studied. Ultimately, the required reaction temperature could be dropped from 400 to below 200 °C, and the reaction time could be reduced from 10 to 1 min whilst achieving 99 % oxalate yield.

Hybridization of Fossil- and CO2 -Based Routes for Ethylene Production using Renewable Energy

Carbon capture and utilization (CCU) has recently gained broad interest in the chemical industry. Direct electro- and thermocatalytic technologies are currently the focus of intense research, where the former employs electricity directly to reduce the CO₂ molecule, while the latter comprises hydrogenation of CO₂ in tandem with electrocatalytic water splitting. So far, it remains unclear which of the two is superior, yet this information is considered critical. Focusing on the platform chemical ethylene, the two CCU routes were compared using state-of-the-art performances with the fossil technology considering different power and CO₂ sources. The thermo-route was found to be, at present, economically and environmentally better, yet under the same electrolyzer efficiencies, the electro-route would become superior. CCU routes could substantially improve the carbon footprint of the fossil ethylene (by 236 %) while decreasing at the same time impacts on human health, ecosystem quality, and resources (64, 140, and 80 %, respectively). However, they are economically unattractive even when considering externalities (indirect cost of environmental impacts), that is, 1.7- to 3.9-fold more expensive compared to the current fossil-based analogue. Acknowledging this limitation, the concept of hybridization was applied as a means to smooth the transition towards more sustainable chemicals. Accordingly, it was found that an optimal hybrid plant could produce carbon-neutral (cradle-to-gate) ethylene with a premium of only 30 % over the current market prices by judiciously combining CCU routes with fossil technologies.

Regionalized Strategies for Food Loss and Waste Management in Spain under a Life Cycle Thinking Approach

Food loss and waste (FLW) has become a central concern in the social and political debate. Simultaneously, using FLW as a bioenergy source could significantly contribute to closing the carbon cycle by reintroducing energy into the food supply chain. This study aims to identify best strategies for FLW management in each of the 17 regions in Spain, through the application of a Life Cycle Assessment. To this end, an evaluation of the environmental performance over time between 2015 and 2040 of five different FLW management scenarios implemented in a framework of (i) compliance and (ii) non-compliance with the targets of the Paris Agreement was performed. Results revealed savings in the consumption of abiotic resources in those regions in which thermal treatment has a strong presence, although their greenhouse gas (GHG) emissions in a scenario of compliance with climate change targets are higher. In contrast, scenarios that include anaerobic digestion and, to a lesser extent those applying aerobic composting, present lower impacts, including climate change, suggesting improvements of 20-60% in non-compliance and 20-80% in compliance with Paris Agreement targets, compared to the current scenarios.

From Laboratory to Industrial Scale: A Prospective LCA for Electrochemical Reduction of CO2 to Formic Acid

CO₂-based production technologies unveil the possibility of sustainable production in the chemical industry. However, so-called carbon capture and utilization (CCU) options do not inevitably lead to improved environmental performance, which is especially uncertain for emerging technologies compared to present production practices. Thus, far, emerging CCU technologies have been environmentally assessed with conventional life cycle assessment (LCA). Therefore, this study aims to develop a methodology for applying prospective LCA to emerging production technologies from the laboratory to industrial scale. The developed four-step approach for implementing prospective LCA is applied to the case of electrochemical formic acid (FA) production via supercritical CO₂ (scCO₂) under consideration of different reactor designs to guide process engineers from an environmental standpoint. While using prospective LCA, the underlying modeling approach relies on consequential LCA (cLCA). Fourteen out of the 15 analyzed impact categories (IC) reveal lower environmental impacts for the scale-ups, which are based on the best-case assumptions and on a flow-through regime compared to the conventional FA production. Nevertheless, the impacts of the scale-ups that are based on a batch reactor (BR) and a three compartment cell (TCC) are higher than for the best case and the flow-through reactor scale-up.