Methanol

The focal point of this work package is the provision of raw gases to the technical center, with a particular emphasis on blast furnace gas (BFG), converter gas (BOFG), and gases derived from DRI processes. The interface between the technical center and the steelwork in Duisburg is significant in this context. Technical issues, such as the variability of operating conditions and differences in the input gases, necessitate meticulous investigation. The primary objective is to guarantee a consistent supply of the necessary gases to the technical center, while concurrently conducting analyses to assess the repercussions of variations in gas composition.

The researchers are developing various concepts for optimizing the technical and economic feasibility of using by-product gases, considering the regulatory framework. The analysis of existing and novel metallurgical gases in terms of availability and composition is imperative to facilitate their long-term integration into the production process. The strategic utilization of CO-containing gases from the steel industry is designed to enhance internal hydrogen production and promote a carbon-efficient, low-emission industry.

Another objective is to further develop the integration of CCU into internal carbon cycles in the steel industry to minimize CO₂ emissions. The analysis of renewable energies and biogenic substitutes is being conducted to enhance the sustainability of the processes. Contemporary control methodologies and mathematical optimization theories are being employed to calculate optimal operating configurations for Carbon2Chem® facilities. The efficacy of these model-based methods is contingent upon the quality of the utilized models. Submodels of the networks and a new methodology for calculating combined operation under variable boundary conditions are being developed to support the transformation of the steel industry over decades.

The effective purification of raw gases is imperative for the provision of synthesis gas that meets the criteria for methanol synthesis. The purification of gas has been demonstrated to have an impact on not only carbon-containing gases from industrial processes, but also hydrogen from alkaline electrolysis at the Carbon2Chem® pilot plant. The availability and purity of hydrogen are contingent upon the operating parameters of the electrolysis process and exert an influence on subsequent processes. The objective is to cultivate a profound comprehension of the interrelationships between the operating parameters of the electrolysis and the resultant impurities to optimize the gas purification process. Consequently, the project partners are concurrently developing and implementing approaches for operational analysis and adaptation of plant operation.

Another research focus is on the separation of CO₂ from raw gases with the objective of extracting CO₂ from heavily contaminated steel mill gases for subsequent synthesis. The objective of targeted investigations into CO₂ absorption is to analyze the behavior and efficiency of absorption under various conditions. The objective of this study is to formulate robust and economical concepts for CO₂ separation that are tailored to the specific requirements of the raw gas sources. The subsequent analysis will entail the formulation of strategies for process gases from disparate industries.

The findings will be systematically compiled to develop a comprehensive strategy for producing a demand-oriented synthesis gas. The results of gas purification, CO₂ scrubbing, and analyses will be combined to develop robust strategies for consistently high-quality synthesis gas that maximizes the efficiency and stability of the subsequent methanol synthesis.

As part of the work package, research data will be collected to investigate the interaction between catalyst composition, deactivation, and by-product formation. The work will be carried out in collaboration with experts from the "System Integration" subproject. The technological approach will be assessed through a pilot-scale implementation involving the utilization of authentic gases. The primary focus of this study is the synthesis of methanol using synthesis gas derived from various metallurgical gases, including BFG and BOFG. The objective of this study is to enhance the efficiency of methanol synthesis using real gas mixtures from steel production. This will be achieved by evaluating the stability and efficiency of the catalyst over extended periods of operation.

A particular emphasis is being placed on the challenges posed by fluctuations in gas composition. Simultaneously, the other work packages aspire to formulate adequate treatment and purification methodologies to minimize impurities in the synthesis gas and protect the catalyst. The results of the planned long-term trials will contribute to the further development and scaling of methanol production and facilitate the transition from the laboratory to industrial scale.

Another research focus is the synthesis of methanol using synthesis gas from industrial sources such as steelworks, cement plants, and biomass gasification. The objective of this study is to apply the synthesis processes to alternative CO₂ sources that have received minimal research attention to date. The scientific work focuses on the simulation and modeling of these processes to develop efficient solutions for gas treatment and create stable production conditions for methanol synthesis.

The objective of this work package is to explore methodologies for downstream processing of the methanol produced, with a particular focus on the integration of methanol (MeOH) derived from metallurgical gases with sustainable, bio-based ethanol (EtOH). The study's objective is to demonstrate that the catalytic combination of MeOH and EtOH to higher alcohols has positive effects on downstream processes.

Another focal point is the planning and implementation of a flexible "MeOH to SAF" pilot plant at the Carbon2Chem® technical center in Duisburg, based on the expertise already gained in technology and process optimization. The pilot plant for producing sustainable aviation fuels (SAF) encompasses all chemical reaction steps of the "MeOH to SAF" technology, including methanol-to-olefins, olefin oligomerization, and oligomer hydrogenation.

The process is undergoing verification and optimization on a continuously operated pilot plant scale, encompassing the long-term operation of all catalysts and their regeneration. A variety of catalysts are employed in the hydrogenation process, with the optimal selection guided by the desired SAF outcome.

A critical component of this process involves the development and optimization of catalysts, which are subjected to rigorous testing and regeneration in a pilot plant setting. Furthermore, the "MeOH to SAF" technology is expected to incorporate mechanisms that facilitate the identification of environmentally harmful components and their replacement with suitable substitutes, thereby mitigating the occurrence of "non-CO₂ effects."