• Energy Research

The current work investigates the feasibility of a novel Carbon Capture and Utilization (CCU) approach—also known as Underground Sun Conversion (USC) or geo-methanation. The overall objective of the current work is a comprehensive assessment on the technical, economic and legal aspects as well as greenhouse gas impacts to be concerned for establishing USC technology concept. This is achieved by applying multidisciplinary research approach combining process simulation, techno-economic and greenhouse gas assessment as well as legal analysis allows answering questions about technical, economic feasibility and greenhouse gas performance as well as on legal constraints related to large scale CCU using geo-methanation in depleted hydrocarbon reservoirs. CO2 from the industry and renewable H2 from the electrolyser are converted to geomethane in an underground gas storage and used in industry again to close the carbon cycle. Process simulation results showed the conversion rates vary due to operation mode and gas cleaning is necessary in any case to achieve natural gas grid compliant feed in quality. The geomethane production costs are found to be similar or even lower than the costs for synthetic methane from Above Ground Methanation (AGM). The GHG-assessment shows a significant saving compared to fossil natural gas and conventional power-to-gas applications. From a legal perspective the major challenge arises from a regulative gap of CCU in the ETS regime. Accordingly, a far-reaching exemption from the obligation to surrender certificates would be fraught with many legal and technical problems and uncertainties.

To achieve the greenhouse gas reduction targets formulated in the European Green Deal, energy- and resource-intensive industries such as the steel industry will have to adapt or convert their production. In the long term, new technologies are promising. However, carbon capture storage and utilization solutions could be considered as short-term retrofitting solutions for existing steelworks. In this context, this paper presents a first experimental demonstration of an approach to the utilization of process off-gases generated in a steelworks by producing methane and methanol in hydrogen-intensified syntheses. Specifically, the integration of two methane synthesis reactors and one methanol synthesis reactor into a steel plant is experimentally simulated. An innovative monitoring and control tool, namely, a dispatch controller, simulates the process off-gas production using a digital twin of the steel plant and optimizes its distribution to existing and new consumers. The operating states/modes of the three reactors resulting from the optimization problem to be solved by the dispatch controller are distributed in real time via an online OPC UA connection to the corresponding experimental plants or their operators and applied there in a decentralized manner. The live coupling test showed that operating values for the different systems can be distributed in parallel from the dispatch controller to the test rigs via the established communication structure without loss. The calculation of a suitable control strategy is performed with a time resolution of one minute, taking into account the three reactors and the relevant steelworks components. Two of each of the methane/methanol synthesis reactors were operated error-free at one time for 10 and 7 h, respectively, with datasets provided by the dispatch controller. All three reactor systems were able to react quickly and stably to dynamic changes in the load or feed gas composition. Consistently high conversions and yields were achieved with low by-product formation.

This work investigates the cost-efficient integration of renewable hydrogen into steelworks for the production of methane and methanol as an efficient way to decarbonize the steel industry. Three case studies that utilize a mixture of steelworks off-gases (blast furnace gas, coke oven gas, and basic oxygen furnace gas), which differ on the amount of used off-gases as well as on the end product (methane and/or methanol), are analyzed and evaluated in terms of their economic performance. The most influential cost factors are identified and sensitivity analyses are conducted for different operating and economic parameters. Renewable hydrogen produced by PEM electrolysis is the most expensive component in this scheme and responsible for over 80% of the total costs. Progress in the hydrogen economy (lower electrolyzer capital costs, improved electrolyzer efficiency, and lower electricity prices) is necessary to establish this technology in the future.

The objective of this article is to demonstrate significant efficiency and performance improvements by simple process modifications of a power to gas plant consisting of high‐temperature coelectrolysis and catalytic methanation. For the advanced process design dual step methanation with two different pressure levels including intermediate compression is proposed, leading to several advantages. By experimental investigations on a lab‐scale methanation test plant higher turnovers (increase of up to 7.1 percentage points) and lower temperature peaks (decrease by up to 130 K) can be proven. Basic energy balance calculations reveal furthermore a reduction in compressor power by 42% for this proposed system.

The by-product gases from the blast furnace and converter of an integrated steelworks highly contribute to today’s global CO2 emissions. Therefore, the steel industry is working on solutions to utilise these gases as a carbon source for product synthesis in order to reduce the amount of CO2 that is released into the environment. One possibility is the conversion of CO2 and CO to synthetic natural gas through methanation. This process is currently extensively researched, as the synthetic natural gas can be directly utilised in the integrated steelworks again, substituting for natural gas. This work addresses the in situ methanation of real steelworks gases in a lab-scaled, three-stage reactor setup, whereby the by-product gases are directly bottled at an integrated steel plant during normal operation, and are not further treated, i.e., by a CO2 separation step. Therefore, high shares of nitrogen are present in the feed gas for the methanation. Furthermore, due to the catalyst poisons present in the only pre-cleaned steelworks gases, an additional gas-cleaning step based on CuO-coated activated carbon is implemented to prevent an instant catalyst deactivation. Results show that, with the filter included, the steady state methanation of real blast furnace and converter gases can be performed without any noticeable deactivation in the catalyst performance.