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110th Anniversary: Evaluation of CO2-Based and CO2-Free Synthetic Fuel Systems Using a Net-Zero-CO2-Emission Framework

Cite this: Ind. Eng. Chem. Res. 2019, 58, 43, 19958–19972
Publication Date (Web):October 1, 2019
https://doi.org/10.1021/acs.iecr.9b00880

Copyright © 2022 American Chemical Society. This publication is licensed under these Terms of Use.

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Abstract

This work analyzes quantitatively the energy and exergy efficiencies of storing intermittent renewable energy in chemical fuels. In the future energy system, chemical fuels provide a very effective approach for long-term storage and long-distance transport of renewable electricity. For the sake of completeness and simplicity, we consider both carbon-free fuels, namely, hydrogen and ammonia, and carbon-rich fuels, i.e., methane and methanol, synthesized using CO2 as the precursor. The latter are called CCU fuels as they constitute an application of CO2 capture and utilization (CCU), which is often advocated to be an effective approach toward climate change mitigation (though no consensus exists). Instead of focusing on the CO2 conversion step, we apply a system-oriented perspective, grounded in the net-zero-CO2-emission framework, to quantify merits and drawbacks. In such a framework, we consider eight systems and technology chains where, in the spirit of a circular economy, the only input is renewable electricity and the only output is a service, consisting in delivering either electricity to the grid on demand (power–fuel–power) or a fuel to propel a means of transportation (power–fuel–propulsion); no fossil carbon is used, and no net CO2 release to the atmosphere occurs. Providing the service of storing renewable electricity in chemical fuels obviously results in a loss of primary energy, which differs in the eight cases considered, depending on the chemical nature of the chemical fuel and on the number and efficiency of the individual steps to synthesize them. Power–CCU fuel–power systems exhibit an energy loss from 65% to 86%, whereas the energy loss of power–CCU fuel–propulsion systems increases to 83–94%. The energy loss of the corresponding systems using ammonia as fuel is similar, whereas that obtained when using hydrogen is significantly smaller, namely, 50–65% and 57–69% in the power–fuel–power and the power–fuel–propulsion case, respectively. Compared to hydrogen, the other energy carriers suffer from increased system complexity and consequently lower efficiency. Exergy analysis has shown low efficiency improvement potential for especially the fuel synthesis step, while the other steps in the chain (electrolysis, extraction from air of CO2 or nitrogen, fuel utilization, and associated compression) still exhibit higher improvement potentials.

1. Introduction

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The reuse of CO2 as a feedstock to produce fuels or chemicals has greatly appealed to scientists, industry, and policy makers, as a way to mitigate climate change and to contribute to a circular economy. (1−5) Since the implementation of CO2 capture and permanent underground storage (CCS) has so far suffered from insufficient public and political support, CO2 capture and utilization (CCU) has been advocated as a valid alternative to mitigate CO2 emissions from power plants and industry. At the same time, the emergence of larger shares of intermittent renewables in the energy system has provided a thrust to search for means of long-term, seasonal storage and long-range transport of renewable electricity; tasks that other electricity storage means such as batteries and pumped hydro are unable to provide. (6,7) For these applications, the production of hydrogen from green electricity and its combination with captured CO2 to form carbon-based fuels could provide an opportunity. These CCU fuels would allow one to keep using existing energy infrastructures that represent billions of dollars of sunk investments instead of switching to completely new energy infrastructures, such as hydrogen networks. (2,8−10)
However, numerous studies have contrasted the optimism above by showing that the CO2 mitigation potential of CCU fuels and other products may often be low, (11−13) that the usable CO2 volumes may be very small, (13,14) and that the costs may be very high. (5,15) This has led to an emerging consensus that CCU in general needs to be considered from a system analysis perspective rather than as a standalone technology, which has so far often been the case. (16) A CCU fuel subsystem would then be analyzed within a larger system that includes harvesting renewable energy (RE), producing hydrogen via water electrolysis, (re)capturing CO2 from point sources or from air, converting CO2 (and hydrogen) into C-rich products (e.g., fuels or chemicals) and using such products, and handling the C-rich waste (most often CO2 again). (16) Initial physical performance indicators of such a system, and of its CCU fuel subsystem, could include the energy use requirements of its components. Key considerations of the analysis of CCU fuel systems include the identification of the need and possibilities to return any CO2 emissions back into the system when emitted.
The use of detailed system analysis, especially techno-economic and life cycle analysis (LCA), is indispensable to present a complete picture of such complex systems. However, sound techno-economic and life cycle analyses require one to input large amounts of detailed data on a rather heterogeneous set of system components, data that may not be readily available at early stages of technology development. In addition, full cost analysis and LCA may require more time than it would be initially justified for new, early stage technologies. Therefore, we here advocate, and apply, a simplified comparative system analysis approach, rather than a detailed environmental and/or economic analysis. This comparative approach is meant as an initial sanity check for novel energy technologies. Rather than a substitute for detailed LCA or economic analysis, it can be used in a complementary way as a means of prescreening. In addition, it is based on merely physical inputs that are often already available early in a technology’s development cycle as well as on indicators that are easy to interpret.
Our comparative approach is based on the framework of a net-zero-CO2 world and of net-zero-CO2 CCU systems functioning within it. We introduce this framework because CCU technologies that are developed now are likely to be deployed in a net-zero-CO2 world: many leading scientists estimate that we may have to reach net-zero-CO2 emissions already by 2050 to fulfill the targets of the Paris Agreement. (17−22) Moreover, the net-zero-CO2-emission constraint drastically simplifies the analysis by eliminating the discussion on how much CO2 is actually mitigated by CCU (or other GHG mitigation) systems: every carbon atom released to the atmosphere must be taken back; every fossil carbon atom produced must be returned to the subsurface. Finally, the simplified and somewhat idealized approach proposed here allows one to draw very insightful conclusions about key features of CCU fuel (sub)systems based on a robust assessment of the technology’s potential regarding physical limitations.
Using the net-zero-CO2 emission framework, we will show that it is technically possible for CCU fuel systems to operate in a net-zero-CO2 world but that such systems face significant challenges in terms of energy efficiency.
This manuscript is organized as follows. In Section 2, we give an illustrative description of net-zero-CO2-emission systems as compared to their net-positive- and net-negative-CO2-emission counterparts. Then, in Section 3, we present the synthetic fuels that we are going to analyze in the net-zero-CO2-emission framework, and we describe the corresponding technology chains for their synthesis using renewable electricity as input and for their use to provide either electricity or propulsion services. In the same section, we describe in detail the methods we use to quantitatively assess the energy efficiency of the eight technology chains considered. In Section 4, we present the results, which include a quantitative assessment of both energy and exergy efficiencies as well as a sensitivity analysis of such values against variations of the input parameters. Finally, we draw conclusions in Section 5.

2. Net-Zero-CO2 World and Net-Zero-CO2 CCU Fuel Systems

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First, to place net-zero-CO2 systems in context, let us define net-zero-CO2-emission systems in an illustrative manner (Figure 1, yellow frame) together with their two counterparts, i.e., positive- and negative-CO2 emission systems (Figure 1, red and green frames, respectively). Nine technology chains are represented. In all but chain 9, the blue boxes represent conversion processes (e.g., a power plant, an airplane, or a chemical factory) delivering a function (either a service or a product), while releasing CO2 from either a point source (amenable to conventional CO2 capture, large blue box) or a distributed source (not amenable, small blue box).

Figure 1

Figure 1. Representation of possible technology chains yielding linear or circular economies, in a net-positive, net-zero, or net-negative CO2-emission system. (16,23) The representation includes fossil-based systems, CCU-fuel-based systems, and bioenergy-based systems. Process units include conventional postcombustion CO2 capture; direct capture of CO2 from air (DAC, requiring C-free renewable energy to operate); biomass conversion plants; CO2 conversion, including an electrolyzer for H2 generation and a collector of C-free renewable electricity (the stylized yellow spark). Arrows represent material fluxes (equipped with storage capacity) of fossil (from the subsurface, red), synthetic (from a conversion plant, blue), biogenic (from biomass, green), or oxidized (CO2, dark gray) carbon. The ultimate CO2 fate can be either release to the atmosphere (light gray cloud) or storage in the subsurface (stylized anticline aquifer).

To assign each of the nine technology chains to one of the three categories, i.e., positive-, negative-, or net-zero-CO2-emission, the following simplifying assumptions are made: the CO2 capture rate is 100%; the yield and selectivity of conversion reactions are 100%; the biomass conversion plant has 100% yield; the use of biomass to generate bioenergy is carbon neutral; CO2 conversion and direct air capture (DAC) of CO2 are powered by C-free renewable energy; no other environmental impact but CO2 emissions is factored in; CO2 underground storage is permanent. Though not completely accurate from an engineering and/or environmental perspective, such assumptions provide a straightforward first-order approximation that serves well the purpose illustrated in the introductory section (when discussing Figure 2, we will make more realistic assumptions, as detailed below).

Figure 2

Figure 2. Block diagram of the power–fuel–power systems investigated: (a) hydrogen, (b) methane, (c) methanol, and (d) ammonia. The blocks include their corresponding pressure levels, energy efficiency, and second-law (exergy) efficiency, and CO2 capture rate in the case of the power plants. The systems’ cyclic efficiency is given in the upper left corners. The supply of electricity to the fuel synthesis and to the DAC/N2-separation units is not represented in the figure for the sake of clarity. For methanol, the source of the CO2 and H2O emissions is the combustion of a purge stream containing CO2 and CO. In the case of methane, the water is a byproduct of the Sabatier reaction and the CO2 is part of the unreacted feed. These are minor streams but are included in the figure for completeness. The abbreviated fuel-to-power conversion plants are hydrogen solid oxide fuel cell (H2SOFC) and gas turbine combined cycle (GTCC). See Figure 3 for the corresponding power–fuel–propulsion chains.

Chains 1 and 7 are deployed today, the former pulling fossil-C from the subsurface and dispersing it as CO2 to the atmosphere (exemplary of a linear economy, L-economy) and the latter using biogenic-C, obtained by photosynthesis from atmospheric CO2 and water, and therefore ideally closing the carbon cycle (paradigmatic of a circular economy, O-economy). Chains 3 and 4 implement CCS with either industrial-scale capture or direct air capture as well as with underground storage. Chains 8 and 9 uptake CO2 from the atmosphere either naturally or via DAC, either supply or demand energy, and store CO2 underground; these are the only two chains in the figure that potentially yield negative CO2 emissions.
Chains 2, 5, and 6 include CCU fuels, whereby the first still belongs to the L-economy, with the fossil carbon being used twice: first in a large-scale plant with CO2 capture and, then, after conversion, in a decentralized unit with CO2 release to the atmosphere, hence with CO2 emissions being reduced by a maximum of 50%. The last two chains realize a closed carbon cycle, indeed a circular economy. Chain 5 on the one hand includes for instance a power–fuel–power technology chain (we use the term “power” here in its colloquial form as an equivalent to electricity, while acknowledging that power is defined in physics as “the rate at which energy is transferred”), whereby the CO2 generated upon burning the C-rich fuel is captured via postcombustion capture. Chain 6 in turn includes for instance a power–fuel–propulsion technology chain, whereby the CO2 emitted by the means of transportation (road vehicle, ship, or plane) is taken back from the atmosphere via DAC. Since chains 5 and 6 belong indeed to a net-zero-CO2-emission world, they are the main subjects of this work and will be analyzed in detail in the following.

3. Methods

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3.1. Technology Assessment Using a Net-Zero-CO2-Emission Framework

On the basis of the discussion in the previous sections, in this work, we analyze CCU fuel using a net-zero-CO2-emission framework by going through the following steps:
1.

Defining the functional unit (or the key product) that the system provides, which is good practice in techno-economic and environmental analysis of energy systems.

2.

Drafting a system diagram of the CO2-positive base system and identifying where in this system there are direct CO2 emissions.

3.

Introducing measures/technologies to return the CO2 emissions back to the system, thus closing the carbon loop.

4.

Calculating performance indicators, which can be the typical technical, economic, or environmental indicators; in this work, we consider only technology first-law and second-law efficiencies, i.e., only technical indicators.

5.

Assessing and comparing the results, i.e., interpreting the calculated indicators and comparing them to alternative systems to gain insight in the relative performance of different options.

CCU fuels will be compared with C-free synthetic fuels, whose synthesis and utilization will also be considered under a net-zero-CO2-emission constraint.

3.2. Case Studies

As indicated in the introduction, a major advantage of synthetic fuels is that they enable long-term (e.g., seasonal) energy storage, because the fuels can be stored with negligible losses and because the amount of energy stored can be decoupled from the capacity of the upstream power uptake and the downstream power generation. This is commonly referred to as power–fuel–power. Moreover, CCU fuels can be used as a transport fuel, where they replace conventional fuels that are based on fossil oil. Such systems are commonly referred to as power–fuel–propulsion. For both cases, we have chosen a functional unit of 1 GW output: 1 GW of electricity in the case of power–fuel–power and 1 GW of propulsion in the case of power–fuel–propulsion.
Two relevant and widely investigated CCU fuels have been chosen for the analysis: (i) methanol (CH3OH or MeOH), which has been discussed for decades as a major energy vector for its relatively easy synthesis from CO2 and subsequent handling, (2) and (ii) methane (CH4), which is obviously of major importance due to the existing natural gas infrastructure and the high efficiency of modern gas-fired power plants. (24) Carbon-free synthetic fuels could also function as synthetic energy carriers, and therefore, we included two for comparison. These are hydrogen and ammonia (NH3), such that the comparison of carbon-based and carbon-free synthetic fuels includes a liquid and a gaseous fuel each (NH3 liquefies at moderate pressures of around 10 bar and is therefore considered as a liquid fuel). Ammonia is receiving increasing attention as an efficient hydrogen carrier and as a fuel, (25,26) and while ammonia combustion and possible nitrogen recycling need additional research and development, NH3 synthesis, transport, and storage are well established. For each of these four cases, a generic system has been designed that fulfils the net-zero-CO2-emission constraint.

3.3. System Design and Infrastructure Requirements

Figure 2 shows the power–fuel–power technology chains as block diagrams. The hydrogen chain depicted in Figure 2a is the most direct power–fuel–power route. The hydrogen is produced through electrolysis, transported, and stored according to time and spatial needs and converted back to power in a fuel cell. To have zero direct CO2 emissions, the electricity fed to the electrolyzer needs to be zero carbon (thus, renewable or nuclear-based). The zero-carbon nature of any energy flow entering the system is an important requirement for net-zero systems; any carbon input needed outside of the system boundaries defined here should be compensated by extracting the equivalent amount of carbon dioxide from the atmosphere. Note that, in each block, the operating pressure (see Section 3.4.2) as well as the efficiency (see eq 1) and the second-law or exergy efficiency (see eq 5) are indicated.
The methane technology chain shown in Figure 2b is significantly more complex. While the first step of hydrogen production via electrolysis is the same as before, an additional conversion unit is required that synthesizes CH4 from H2 and CO2. The technology block for power generation from methane is assumed to be a gas turbine combined cycle (GTCC) with postcombustion CO2 capture, which recycles 90% of the generated CO2. The remaining CO2 emissions from the power plant and the emissions from the fuel synthesis unit are here assumed to be balanced by a DAC unit (for the sake of simplicity, we do not consider here uptake of CO2 from the atmosphere via biomass growth). The technology chain for methanol in Figure 2c obviously has a very similar structure and entails the same technology assumptions as for the methane system. The power–NH3–power chain in Figure 2d includes the separation of nitrogen from air and an ammonia synthesis step in addition to the H2 generation via electrolysis that is common to all four chains, but it reduces the complexity compared to the C-based fuels, because the recovery of CO2 from the power plant is not required (and because the theoretically feasible recycling of N2 from combustion was omitted).
The storage needs of the different technology chains depend on the operating strategies of the individual technology blocks. Power generation and hydrogen production from surplus RE will intuitively operate asynchronously in order to fulfill the purpose of electric energy storage. To that end, one or more of the chemical compounds present in the electricity storage systems need to be temporarily stored.
For power–fuel–power systems (Figure 2), this could be accomplished in different ways:
  • Concurrent operation of fuel synthesis and final power generation: this strategy minimizes the need for fuel and CO2 storage, while hydrogen storage is needed as it effectively bridges the time between RE input and electricity generation. Such operation however foregoes the advantage of the synthetic fuels over H2 in terms of specific volumetric energy density. It also requires the synthesis plant to run as flexibly as the power plant, which may be unwanted from a plant performance and from a capital cost recovery perspective.

  • Synchronizing the operation of electrolysis and fuel synthesis: this strategy minimizes the need for H2 storage, as H2 is directly converted to fuel. However, large-scale storage both of the synthetic fuel and of CO2 (since the GTCC power plant with CO2 capture operates asynchronously to the electrolyzer) is required as a consequence, and the same operational and economic issues of flexible operation of the synthesis plant arise.

  • Fully independent operation of the fuel synthesis plant, either maximizing its capacity factor or operating it flexibly; this strategy requires storage of significant amounts of H2, of synthetic fuel and, for carbon-based fuels, of CO2.

For power–fuel–propulsion systems (Figure 3), neither is the final use of the fuels synchronized with the availability of renewable electricity, nor can the CO2 generated in the final conversion of the CCU fuels be recycled to the fuel synthesis. Consequently, CO2 capture (via DAC or BECC) and fuel synthesis can be synchronized, and the need for CO2 storage minimized. Depending on the operating strategy, large-scale storage of either H2 (capacity factor of fuel synthesis maximized) or synthetic fuel (fuel synthesis synchronized with renewable energy) is required.

Figure 3

Figure 3. Block diagram of the four power–fuel–propulsion systems investigated: (a) hydrogen, (b) methane, (c) methanol, and (d) ammonia. The blocks include their corresponding pressure levels, energy efficiency, and second-law (exergy) efficiency and CO2 capture rate in the case of the power plants. The systems’ cyclic efficiency is given in the upper left corners. The supply of electricity to the fuel synthesis and to the DAC/N2-separation units is not represented in the figure for the sake of clarity. The pressure indicated in the final conversion blocks represents the vehicle’s tank. For methanol, the source of the CO2 and H2O emissions is the combustion of a purge stream containing CO2 and CO. In the case of methane, the water is a byproduct of the Sabatier reaction and the CO2 is part of the unreacted feed. These are minor streams but are included in the figure for completeness. The abbreviated fuel-to-propulsion technologies are hydrogen polymer electrolyte membrane fuel cell (H2PEMFC), internal combustion engine (ICE), and direct methanol fuel cell (DMFC).

In summary, from a system design perspective, net-zero-CO2-emission power–CCU fuel–power systems need the following elements in addition to their CO2 positive counterparts: CO2 capture means, fitted to fuel combustion plants and complemented with CO2 capture from the air via DAC or BECC; large-scale intermediate storage of at least one of the involved chemical compounds, be it hydrogen, CO2, the CCU fuel, or all three.

3.4. Thermodynamic Analysis Assumptions

3.4.1. Building Blocks

The general building blocks that were used within the net-zero-CO2-emission framework include hydrogen production, fuel synthesis, gas separation (i.e., CO2 or N2), fuel combustion, fuel/feedstock compression, and intermediate fuel/feedstock storage. For the thermodynamic analysis, these generic blocks were filled with specific technologies. We used the corresponding technologies that have advanced the furthest: wherever possible, commercial technologies were used; when necessary, technologies that are in pilot or demonstration phase were applied. The rationale behind this criterion for selection was to assess the potential of synthetic fuels under realistic assumptions, being rather optimistic than conservative for technologies still at the demonstration stage. The individual technologies used in the technology chains are illustrated in Figures 2 and 3, and their features are reported in Table 1. In particular, the second and the third columns report the electricity and the heat input per unit product synthesized, respectively, whereas the fourth column shows the conversion efficiency with respect to the lower heating value (LHV); the last column reports the source of the previous data. Note that all technologies, with the exception of ammonia conversion in an internal combustion engine (ICE), are commercial or precommercial.
Table 1. List of Individual Technologies Used in the Technology Chains Illustrated in Figures 2 and 3 and Their Features
building blockelectricity input requirement (MWh/t product)heat input requirement (MWh/t product)conversion efficiency (LHV) (%)data source
direct air capture0.251.750 manufacturer estimatea
fuel synthesis methanol0.1690.439 modeling studyb
fuel synthesis methane0.33–3.008 pilot plantc
fuel synthesis ammoniab0.030 modeling studyd
N2 production (air separation unit) (45)0.020 manufacturer datae
H2 compression from 30 to 700 bar23  Aspen Plus modelf
CH4 compression from 8 to 66 bar1.78  Aspen Plus modelf
CH4 compression from 66 to 250 bar0.89  Aspen Plus modelf
H2 production (electrolysis at 30 bar)  70literature and manufacturer datag
H2 PEM FC  60manufacturer datah
direct methanol FC  35prototype and modeling studyi
H2 SOFC  61manufacturer data and modeling studyj
GTCC w/o CO2 capture  59modeling study based on vendor datak
GTCC with CO2 capture  51modeling study based on vendor datak
fuel conversion methane ICE  22manufacturer data/US EPA driving cycle testl
fuel conversion ammonia ICE  22prototype
subcritical steam cycle efficiency  30modeling studym
biomass power plant with CCS  28modeling studyn
biomass power plant without CCS  38modeling studyn
charger/inverter  95modeling studyo
battery  95modeling studyo
electric drive  90modeling studyp
hydrogen-fired boiler  85manufacturer dataq
a

Climeworks estimate. (30)

b

Values used from the process modeling study by Pérez-Fortes et al., (5) based on the process by Van-Dal and Bouallou. (32)

c

Values retrieved from ref (28), which uses pilot plant results reported by Müller et al. (46)

d

Based on George and Richards (38) (as cited by Avery (36)).

e

Industry value reported by Castle, (45) as cited in Grinberg Dana et al. (26)

f

Compression energies were taken from Aspen Plus, using a 72% isentropic efficiency. An eight-stage integrally geared compressor with intercooling to 35 °C was assumed for H2 and CH4 compression to propulsion pressures.

g

An electrolyzer efficiency of 70% was used on the basis of refs (8and27) where Siemens reports a 75% efficiency of their largest electrolyzer model. (47,48) Late 2000 to early 2010 vendor inquiries by NREL indicate LHV efficiencies between 61% and 66%. (49,50) A 70% LHV efficiency corresponds to an electricity demand of 48 MWh/t_H2.

h

Manufacturer data as collected by the US DOE. (44)

i

Based on DMFC prototypes and modeling studies. (33,34,51)

j

Based on the modeling study in ref (43); manufacturer data collected by the US DOE states efficiencies of 60%. (44)

k

Modeling study based on gas turbine and CO2 capture plant data from vendors. (29)

l

Data from car manufacturers and US EPA was used for midrange ICE vehicles running on natural gas. (52)

m

Based on NETL (53) and Muñoz et al. (54)

n

Based on a modeling study by DOE/NETL, reported in Schakel et al. (55)

o

Using modeling assumptions reported by Van Vliet et al. (56)

p

Values used from a modeling study by Pellegrino et al. (57)

q

Manufacturer data from Cleaver Brooks. (58)

The hydrogen is produced in all cases by water electrolysis using polymer electrolyte membrane (PEM) technology. (27) For the methane zero-emission loop that produces 1 GW of power as a functional unit, the specific building blocks included methane (Sabatier) synthesis (28) (including a subcritical steam turbine cycle to recover released heat), combustion of the fuel in a GTCC with CO2 capture and compression, (29) and DAC of CO2 to capture residual CO2 emissions. The Climeworks process (30) was selected for DAC because it is already deployed precommercially, with several units built, and in operation. It is worth noting that, since the same technology for DAC is used in all calculations, the comparative evaluation of the four power–CCU fuel–power and power–CCU fuel–propulsion systems is not affected by the choice of the specific DAC technology and its relevant performance parameters. The sensitivity analysis carried out in Section 4.4 accounts for uncertainties in the performance parameters of DAC that are larger than the declared differences among currently known technologies. GTCC technology was selected because it represents the current state-of-the-art in gas-fired, centralized power generation. When methane was used to provide a functional unit of propulsion, we assumed that it is burned in an internal combustion engine (ICE), as usable low temperature direct methane fuel cells are currently still in a preliminary stage of development, (31) while methane ICEs are in wide use.
For the methanol technology chains, we used the single step methanol synthesis by CO2 hydrogenation, studied earlier by Pérez-Fortes et al. and Van-Dal and Bouallou. (5,32) For the production of a functional unit of power, we assumed that methanol was also combusted in a GTCC with CO2 capture and compression, assuming the same efficiency as for natural gas. For a functional unit of propulsion, we chose to use a direct methanol fuel cell. (31,33,34) For the ammonia power–fuel–power system, we also assumed that it is burned in a gas turbine coupled with a combined cycle. While early research and demonstration highlighted the potential for reaching higher electric efficiencies than with conventional hydrocarbon fuels, (35,36) we conservatively assumed the same conversion efficiency as for a natural gas combined cycle without CO2 capture and compression. Although conventional ammonia plants generate hydrogen via natural gas reforming, we used a route that generates H2 via electrolysis and N2 with an ASU to make it comparable to the other synthetic fuels. This production route exists commercially (37) but is less common than the reforming route. The energy demand for feed gas compression in the ammonia synthesis unit was determined from the integrated process design of George and Richards (38) (as cited by Avery (36)). The high efficiency of the synthesis is in agreement with the energy analysis of conventional processes, which have identified the major losses to occur in the, in our case obsolete, reforming section. (39,40) We applied the energy demand for ASU as compiled by Grinberg Dana et al. (26) For propulsion, ammonia combustion in an ICE was assumed to have the same efficiency as methane. (41,42) Finally, for the hydrogen case, we assumed combustion in fuel cell systems: a solid oxide fuel system for the power application (43) and a polymer electrolyte fuel cell for the propulsion application. (44) Before use in the vehicle, the hydrogen is assumed to be compressed to 700 bar, using an isentropic compression efficiency of 72%.

3.4.2. Pressure Levels

The pressure levels selected as reported in Table 2 determine compression energies and storage densities.
Table 2. Transmission and (Intermediate) Storage Pressure Assumed in This Work and Their Corresponding Densitiesa
gaspressure (bar)corresponding density (kg·m–3)
hydrogen302.4
CO2150876
N2100113
methane6648
methanol1790
ammonia10603
a

Note that when hydrogen or methane are used for propulsion, they are pressurized at the filling station to pressures of 700 and 250 bar, respectively.

Methane and methanol production are reported to take place at elevated pressure; this work assumed 30 bar for both, equivalent to Pérez-Fortes et al. (5) and in line with studies on CO2 methanation. (27,59) The methane transmission pressure in Europe is typically between 60 and 70 bar. IEAGHG assumes 66 bar; (29) we adopted this value here. In the case of propulsion, the methane was assumed to be compressed to 250 bar at the fuelling station. As methanol is liquid at ambient pressure, it is assumed that its transport infrastructure operates at 1 bar. Where pressure differentials exist between the operating pressures in the individual building blocks and the transport infrastructure, these were accounted for by additional compression or expansion.
Also, hydrogen was assumed to be produced, transported, and stored at 30 bar. Assumptions on hydrogen transport and storage values vary. Existing hydrogen networks include fairly modest pressures of 25 bar (60) and up to higher pressures of 110 bar. (61) The UK H21 project reports hydrogen storage pressures of 20–60 bar for short-term storage and up to 200 bar for seasonal storage. Only in the case of use for mobility purposes is hydrogen compressed at the fuelling station to 700 bar.
CO2 storage is likely done at high pressure; in the US, a value of 150 bar is typically assumed. (62) Given the necessity of intermediate (geological) CO2 storage, we assumed this pressure for the entire CO2 network.

3.5. Efficiency Analysis

The quantitative comparison of the four power–fuel–power and power–fuel–propulsion systems has been carried out on the basis of chain efficiencies, which are defined as ratios of the generated electric or propulsion energy, respectively, and the ingoing renewable electricity. The efficiency of the individual blocks reported in Figures 2 and 3 is based on the lower heating value (LHV) of the fuels and on electric energy. Heat demands, which occur in the DAC and in the methanol synthesis block, are converted into the calorific value of H2. In order to guarantee flexibility in the operating strategy of the plant, it is assumed that H2 is burned to cover these heat demands, independent of the current availability of intermittent RE. The heat rejected by the methane synthesis is converted to electricity applying a subcritical steam cycle. Efficiencies are taken directly from the literature for the electrolysis and the final conversion step and calculated for the fuel synthesis as follows
(1)
where W is electric energy or propulsion work, Q is heat, ηelec is the efficiency of the electrolyzer, ηboiler is the LHV efficiency of a hydrogen boiler, mi is the mass of component i in the feed stream, mj is the mass of component j in the product stream, and ΔHLHV is the enthalpy of combustion of each feed or product species.
We also calculated how much each block contributed to the total efficiency loss of the overall system
(2)
where ΔUblock is the energy loss over a block and WRE,in is the total renewable energy entering the chain. Note that here, the heat input for DAC or for synthetic fuel synthesis units is included in the term Δ(ΣmiΔHiLHV), since we have assumed this to be supplied by hydrogen, which is burnt in a boiler to supply heat.

3.6. Second-Law Analysis

The individual blocks were analyzed in terms of second-law efficiencies in order to study their level of perfection, i.e., the thermodynamic potential for further improvement. In order to consider the value of purified noncombustible materials (CO2, N2), exergy efficiencies were calculated, where relevant, by applying the specific exergy of the feed and product components instead of the calorific values (i.e., LHV). Exergy, or availability, is defined as the maximum theoretical work that can be obtained from a system as it interacts with its environment toward equilibrium, and it is based on the second law of thermodynamics. (63) The specific exergy comprises a chemical (ech) and a thermomechanical (eth) contribution.
(3)
The two terms were determined using the tabulated values of Szargut et al. (64) and temperature and pressure specific enthalpy and entropy data reported by NIST, (65) respectively. The exergy of sensible heat was calculated using the Carnot efficiency
(4)
where T0 is the ambient temperature of 298 K.
The exergy efficiency of the individual blocks was defined as
(5)
where ηST is the subcritical steam cycle efficiency reported in Table 1. Note that the methane synthesis is the only block in the current analysis, where ηST was applied, since it is the only block for which the modeled technology assumes the export of power from excess heat. We chose to use the steam cycle efficiency instead of a Carnot efficiency in order to highlight the improvement potential of the technology block as it is modeled in this work, i.e., including improvements in the use of the excess heat compared to the current use in a subcritical steam cycle. The synthesis blocks of MeOH and NH3 utilize the heat generated by exothermic reactions for internal purposes.

3.7. Sensitivity Analysis

The local (single parameter) sensitivity analysis in this work focused on the sensitivity of net system efficiency to changes in technology specific input values. Minimum and maximum input values were investigated for the electrolysis efficiency, the energy use of DAC and ASU, the energy use (and production in the case of methane) of the fuel synthesis technologies, and the efficiency of the fuel conversion technologies. The minima and maxima were mostly selected based on real lower bounds and optimistic upper bounds (sometimes realistic, sometimes assuming the max theoretical efficiency where the current state of technology is already close to reaching that). The exact values are included in Figure 7, and some assumptions are highlighted in the text below.
For electrolysis, we used 2013 efficiency quotes from 4 vendors, as reported by NREL, (50) as the lower end (61%LHV efficiency), which likely includes the balance of plant and cycling inefficiencies. (8,49) Siemens currently reports an efficiency of 75%LHV, (48) and because this is close to our base assumption of 70%LHV, we rather assumed the maximum theoretical LHV efficiency of 82% (49) as the upper limit. For DAC, we used power and heat consumptions of 150 and 1200 kWh as a lower bound, based on a presentation by Global Thermostat. (66) As the upper bound for the electricity consumption, we used 500 kWh, twice as large as our base case. We used an upper heat input of 2500 kWh, which is our own estimate.
For fuel synthesis, we aimed at representing the most favorable set of assumptions possible for the high end. This implies that reactions would occur with ideal stoichiometry assuming that equilibrium limitations are overcome through recycling of the unreacted reagents. Any consumption of heat and electricity is neglected, and any rejected heat (exothermic reactions) is converted to electricity assuming a Carnot efficiency. Additionally, any release of CO2 from the synthesis plant, e.g., through purge streams, is captured with a 100% CO2 capture rate and with a negligible energy requirement. For the low end, we increased all energy and heat requirements of the fuel synthesis step by 50%. These inputs are already small, and increasing them by a lower percentage would not lead to notable changes in output.
For hydrogen conversion to power, we used the lower value of 49% calculated by Peters et al. (43) as our lower bound. The higher bound was set based on the DOE EERE long-term target (70%). (31) For the carbon-based fuels, we selected an upper efficiency value assuming replacement of GTCC’s with natural gas fuel cells with fuel pre-reforming and integrated CO2 capture (with a capture rate of 99.5%). The lower efficiency value assumes combustion in open cycle gas turbines (OCGT) (67,68) with a CO2 capture efficiency penalty of 10% pts. For ammonia conversion to power, also fuel cells and OCGTs were assumed as the most and least efficient technologies, although the OCGTs are without CCS in this case, and therefore, their efficiency is higher.
Finally, the minimum and maximum values for fuel conversion to propulsion depend on the fuel type. For hydrogen, we assumed a PEM fuel cell maximum efficiency of 70%, in line with the DOE EERE long-term target. (31) Since the current PEMFC efficiency is approximately 60%, (31,44) it was assumed that the minimum fuel cell efficiency is 50%. For DMFCs, Rashidi et al. (34) report a modeled efficiency range from 20% to 45%, which was adopted here. For (compressed) natural gas combustion in ICEs, Curran et al. (52) used a tank-to-wheel efficiency range of 14–26%, based on various driving cycle tests reported by the US DOE and EPA. One of the sources behind the DOE range is Thomas, (69) who derive combined highway/city tank-to-wheel efficiencies from EPA dynamometer driving cycle tests on 34 passenger vehicles. These data are however for gasoline ICEs, and Zamfirescu and Dincer (70) report that compressed natural gas (CNG) vehicles have an efficiency some 4% higher than gasoline vehicles. Adding another 5% potential upside in ICE development in the next decades, we adopted a maximum efficiency of 35% for CNG ICEs, while using the lower value of 14% reported by Curran et al. (52) For the ammonia ICEs, Mørch et al. (71) measured 5% higher ICE efficiencies for high ammonia (>90%)/low hydrogen (<10%) mixtures compared to petrol ICEs. We therefore adopt the same upper bound as for the CNG ICEs of 35%. This is in line with the ∼45% efficiency reported for a very novel high pressure ratio ammonia ICE design, (70) when subtracting a 10% pt efficiency loss for the drive train and parasitic losses. (72) As a minimum efficiency for the ammonia ICE, we also adopted the lower bound of 14% of Curran et al. (52)

4. Results and Discussion

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4.1. Primary Energy Loss over the Power–Fuel–Power Chains

When the synthetic fuels in a power–fuel–power cycle are analyzed, a large loss of primary renewable power over the system is observed (see Figure 4a and the Supporting Information). Figure 4a shows that the net-zero-CO2 power–methane–power system loses more than 70% of the primary renewable power, most of which is due to the electrolysis step and to the fuel combustion in the GTCC with carbon capture. A much smaller loss is observed in the methane synthesis step (approximately one-third of the loss in either electrolysis or GTCC), and a minor amount is lost in the DAC operation. In order to better illustrate the comparison, the waterfall diagrams of Figures 4a and S1–S4 have been collapsed into stacked bars in Figure 5. Here, methanol and ammonia show a similar pattern as methane, with electrolysis and fuel combustion representing the major losses. For methanol, the losses attributed to DAC increase compared to methane, due to a higher carbon content of the fuel per unit calorific value. The energy demand for the separation of nitrogen from air in the ammonia chain is significantly smaller than the corresponding demands for CO2 separation for methane and methanol, owing to an advantageous stoichiometry and to the fact that the nitrogen concentration in air is 3 orders of magnitude higher than that of CO2. The fuel synthesis steps exhibit similar losses for all three fuels involving fuel synthesis. In the hydrogen system, the losses are limited to electrolysis and fuel combustion, each contributing to a similar extent.

Figure 4

Figure 4. Waterfall diagrams of power–methane–power (a) and power–methanol–propulsion (b).

Figure 5

Figure 5. Breakdown of primary renewable power losses and resulting cycle efficiencies to produce 1 GW of power and/or propulsion (using DAC for the CCU fuel systems). The darkest color represents the relative energy output of each chain. H2 compression occurs only in the hydrogen for propulsion chain, where additional compression is required after electrolysis. “Air separation” indicates the efficiency loss related to DAC for the CCU fuels and to N2 separation for ammonia. “Air separation” and “fuel synthesis” do not occur in the hydrogen chains. Of the chemical energy carriers, hydrogen has the highest cycle efficiency, especially when providing propulsion in a transport application. The biggest losses are incurred in all systems in the electrolysis and fuel combustion steps, not in the fuel synthesis step. For the CCU propulsion cases, these losses are complemented with a large loss for direct air capture of CO2.

Comparing the four energy carriers, Figure 5 shows that the net cycle efficiency of the hydrogen system is the highest, with a value of approximately 43%. Also, ammonia has a higher efficiency (36%) than the CCU fuels (26–28%). This confirms earlier studies on the assessment of chemical energy carriers (8,26,27) in a linear (non net-zero-CO2) system. In the net-zero-CO2 assessment, the need to introduce air capture of CO2 only increases the difference between CCU fuels and hydrogen or ammonia. Overall, the efficiency cost of facilitating long-term, seasonal, electricity storage by means of power–fuel–power chemical energy storage in synthetic fuels is high; i.e., more than half of the energy is lost.

4.2. Primary Energy Loss over the Power–Fuel–Propulsion Chains

The investigation of the power–fuel–propulsion cycle for hydrogen (blue bars in Figure 5) shows only a minor efficiency reduction compared to its power–fuel–power cycle, due to the additional compression to 700 bar typical for mobility applications and a slightly lower efficiency of the final energy conversion step (PEMFC instead of SOFC; see Figure 2). All other fuels show a drastic reduction of the cyclic efficiency to between 9% and 13%. Significantly higher losses occur in the final energy conversion step, where the availability of a fuel cell for mobility applications represents a competitive advantage for methanol (DMFC, 35% LHV efficient) compared to methane and ammonia, where ICEs (22% LHV efficient) are considered to be the state-of-the- art.
In addition, the nonavailability of the CO2 recycle from the combustion to the fuel synthesis, due to technical and logistical impracticalities, leads to a drastic increase of the DAC utilization and of the corresponding energy requirements (see Figures 4b and 5 and the Supporting Information). This is a large difference to net-positive power–fuel–propulsion systems that only reuse the CO2 once. In a net-zero-CO2 setting, the CCU fuels thus perform substantially worse than in a net-positive (the classical) setting. Overall, the hydrogen system is approximately three times more efficient than the systems based on CCU fuels and on ammonia. Its intrinsic advantage (i.e., lower complexity due to the avoidance of the separation/extraction from the atmosphere and of the fuel synthesis) is even clearer in the power–fuel–propulsion chains than in the power–fuel–power systems. In addition, the H2–PEMFC is the most efficient fuel-to-propulsion energy conversion technology today, when only energy efficiencies (hence, only operating costs) are considered. Such a result should of course be considered together with the costs associated with the implementation of the different technology chains before making strategic decisions about infrastructure development.
In order to guarantee flexibility in the operating strategy of the individual blocks, the base case assumes that the heat demands of DAC and of the fuel synthesis (namely, MeOH synthesis) are covered by hydrogen-fired boilers. In times when RE is available, direct electric heating could be applied, such that the inefficiencies of electrolysis and the H2 boiler are avoided. For the low-quality heat demand of the adsorption-based DAC units at around 100 °C, high-temperature (HT) heat pumps could further improve the efficiency in such times. However, the effect on the chain efficiencies is limited, even if the availability of RE is assumed to be temporally unlimited and a HT heat pump with a COP of 2 is used to cover the DAC heat demand. The resulting chain efficiencies are 29.1% and 27.4% for the CH4 and MeOH power–fuel–power chains and 11.1% and 16.4% for the CH4 and MeOH power–fuel–propulsion chains, respectively.
One argument in favor of CCU fuels has always been that they allow for easier storage and transportation over long distances than hydrogen. The very high cyclic energy losses they incur could therefore be seen as the efficiency cost of ease of long-term (seasonal) storage and of long-distance transportation. Having said that, since hydrogen for transportation purposes can largely be produced on-site at the fuelling station if the required carbon-free renewable electricity is available, (73) the ease of transportation argument for liquid fuels may not hold in every case. Finally, another important consideration on the use of synthetic fuels for seasonal power storage combined with propulsion services is the following: it would be more efficient to store renewable power using power–methane–power and let vehicles drive using the electricity generated in this way, which would yield a 22% cyclic system efficiency (assuming a charger to wheel efficiency of 77.2%, based on literature data (56,57)), than to use CCU fuels or ammonia to power vehicles directly (9–13% cyclic efficiency).

4.3. Analysis of Efficiency Improvement Potential by Exergy Analysis

Exergy analysis, for example, through determining the second-law efficiencies of eq 5, can be applied to identify unit operations in a production process, where exergy is lost, and thus to focus the attention on system elements that offer the largest opportunities for improvement. (63,74) A second-law efficiency of 100% refers to a perfectly reversible process, such as a Carnot cycle, that does not incur any loss of available work (i.e., of exergy).
The efficiencies presented so far were defined in terms of calorific value of the fuels (LHV) and of electricity. Heat streams have been converted to the calorific value of the fuel that is burned in a boiler to generate the heat or to electricity via a subcritical steam cycle. The exergy analysis uses specific exergy instead of calorific value and converts heat demands to exergy by applying a Carnot cycle efficiency at the corresponding temperature. Electricity is 100% recoverable work and does not have to be converted.
For the air separation unit (ASU), for DAC, and for the GTCC with CO2 capture, only an exergy analysis allows one to account for the nonenergetic but purified product species, namely, CO2 and N2, by considering their chemical and thermomechanical exergy (74) (for details of the calculation, see Section 3.5 and the Supporting Information). For electrolysis and fuel synthesis, however, the energy efficiencies reported in Figures 2 and 3 are dominated by electric energy and the calorific value of the fuels. While the second-law efficiencies presented in Figure 6 consider the exergy of educts and products instead of their calorific value, the results do not differ significantly, because the specific exergy of fuels is largely defined by their calorific value. Nevertheless, the second-law efficiency of 70% for the electrolysis confirms that there is still potential for improvement of the energetic performance, besides the current efforts to improve flexibility and ramping. All three fuel synthesis steps exhibit second-law efficiencies of around 90%, which is due to a high efficiency in converting the chemical exergy of H2 into chemical exergy of the synthetic fuels, assuming nearly stoichiometric reactions, and due to the fact that all reactions are performed at significant pressure and temperature; thus, the heat released from the exothermic reactions can be used effectively to generate steam that then serves internal demands or provides electricity.

Figure 6

Figure 6. Comparison of the second-law efficiency of each system block and of its contribution to the efficiency loss for the power–fuel–power systems. The graph shows that the synthesis step of the synthetic fuels is already highly efficient, as shown by the high second-law efficiency. Fuel synthesis however has only a small impact on the cyclic efficiency loss over the overall system. Electrolysis and fuel combustion in a GTCC (with or without CCS) contribute much more to the overall cyclic efficiency loss, and they still exhibit quite some room for efficiency improvement, especially fuel combustion. DAC shows the highest potential for second-law improvement but has the lowest contribution to the cyclic efficiency loss.

The second-law efficiencies of the final energy conversion units and of the DAC/ASU units are relatively low. For power plants that involve combustion, such low efficiencies are commonly known and to a large extent related to the inability of exploiting the high combustion temperatures effectively and to the resulting exergy losses associated with the hot flue gas. The low exergetic efficiency of cryogenic air separation is also confirmed in the literature, (64) whereas the DAC unit performs comparatively well under the current assumptions.

4.4. Discussion

To assess the robustness of the results obtained in terms of efficiency in the use of renewable electricity, we have performed a local sensitivity analysis on the key input parameters. These were varied in an interval defined by lower and upper bounds, selected specifically for each input parameter to provide an evaluation of what realistic performance ranges are. For some parameters, vendor indications of performance were used, and for others, measured or modeled scientific data were used. For the fuel synthesis steps and electrolysis, the maximum theoretical efficiency was selected for the upper values. For methane conversion to power, we selected as lower and upper bounds other technologies than GTCC with CCS, i.e., open cycle gas turbine with CCS and a natural gas fuel cell system with CCS. Further assumptions and the parameter ranges are indicated in Figure 7 and explained and justified in Section 3.6.

Figure 7

Figure 7. Sensitivity of net system efficiency to changes in electrolysis, DAC/ASU, fuel synthesis, and fuel conversion. The second column from the left indicates how the input parameters were varied, represented on a 0–100% scale where possible. The resulting range of chain efficiencies is reported on the right with the middle line representing the base case. The input parameter assumptions are given as efficiency for electrolysis and final conversion and as an energy requirement for DAC/ASU. For fuel synthesis, see the corresponding text.

Figure 7a shows the results of varying the input parameters on net cycle efficiency of the power–fuel–power cycles. It is immediately apparent that the comparative ranking of the technologies remains the same, no matter which type of parameter is varied. This means that hydrogen remains the most efficient, followed by ammonia, methane, and methanol. It is also clear that all technologies exhibit rather large ranges of possible efficiencies due to the uncertainty in the performance of electrolysis and final fuel conversion steps. This means there is potential for improvement for each of the systems if and when high efficiency electrolysis and final fuel conversion are brought to the market, but it similarly means that, when legacy systems with lower efficiency are used, the chain efficiency will be low. For electrolysis, it means that the high efficiencies quoted by vendors should also be reached during flexible operation and not only during optimal steady state conditions. The figure also shows that improvements in DAC/ASU and fuel synthesis have a significantly smaller effect on the chain efficiency: the former due to its small contribution to the overall efficiency loss (see also Figure 6) and the latter due to its already high exergy efficiency (Figure 6). It is worth noting that the high end of the sensitivity shown for the synthesis reaction represents a highly idealized situation, assuming not only perfect exergy efficiency and ideal reaction stoichiometry but also 100% CO2 capture within the synthesis step (and the inherent secondary effect of lower DAC demands). This indicates that, for the efficiency improvement of net-zero-CO2-emission capture CCU fuel, hydrogen, or ammonia systems, the focus should be on improving the efficiency of electrolysis and fuel conversion, more so than on improving that of direct air capture and fuel synthesis. Figure 7a also reconfirms the potential of ammonia as a carbon-free energy carrier that, contrary to hydrogen, is liquid at moderate pressure.
For power–fuel–propulsion, the ranking of technologies also remains the same (Figure 7b), meaning that the efficiency of the hydrogen system prevails over those of ammonia, methanol, and methane. For the propulsion chains, most upside, but also downside, comes from the performance of the fuel conversion step, meaning that high efficiency technologies for the final conversion (be it ICE or FC or other) should receive research priority when developing synthetic chemical energy carriers for transportation purposes. Especially, the development and commercialization of methanol (e.g., direct methanol fuel cells) (33,34) and ammonia (e.g., high-pressure ratio ammonia engines) (70) conversion technologies could contribute to improve the efficiency of liquid chemical energy carrier chains, even though this will not yet close the gap with hydrogen.

5. Conclusions

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This work has analyzed technologies for the seasonal storage of renewable electricity (RE) in synthetic fuels, either carbon-based (methane and methanol) or carbon free (hydrogen and ammonia), under the strong constraint that all technology chains investigated yield net-zero-CO2 emissions.
As a first result, this net-zero-CO2-emissions framework has allowed one to identify relevant requirements on the technological characteristics enabling net-zero CCU fuel systems. First, these systems need CO2 removal technologies to remove residual CO2 emissions from the air. Second, they require zero-CO2 hydrogen production. Third, net-zero-emission power–CCU fuel–power systems need intermittent storage not only of hydrogen but also of CO2 and/or synthetic fuel to overcome periods without sufficient RE generation, thus implying that major geological storage facilities shall be in place.
We conclude that the efficiency cost of facilitating long-term storage and long-range transport of RE by means of synthetic fuels is high to very high: power–fuel–power chains lose between 60% of the original RE in the case of hydrogen to more than two-thirds in the other three cases. Power–fuel–propulsion chains lose between two-thirds in the case of hydrogen to about 90% in the other three cases.
Using exergy analysis and sensitivity analysis, we have demonstrated that the potential for efficiency improvement is the highest for technologies that separate carbon dioxide or nitrogen from air which, however, have a small effect on the overall system efficiency. The efficiency improvement potential is the lowest for the methane, methanol, and ammonia synthesis technologies. Moreover, there is still improvement potential for hydrogen production by electrolysis and for the final fuel-to-power (with CO2 capture in the case of carbon-based synthetic fuels) and fuel-to-propulsion steps, which have a large effect on the overall system efficiency. These observations are relevant as they may lead to a prioritization of research and innovation needs, more specifically less in favor of methane, methanol, and ammonia synthesis and more in favor of electrolysis for renewable hydrogen production and of final fuel conversion for both power generation and propulsion. The analyses in this paper thus show clear shortcomings in terms of efficiency in the use of RE of the CCU fuels (and to a lesser extent of ammonia). This implies that other advantages (infrastructure-related, economic, environmental, related to safety and public perception) of CCU fuels over carbon-free alternatives need to be rather significant to make them competitive. From a systems perspective, this may mean that these fuels may only be used in applications where they are really needed and where alternatives cannot fulfill the same function, such as air travel, for example.
The net-zero-carbon framework applied in this paper shows those things clearly, and we believe it is therefore very useful to generate a first important level of understanding of the potential of CCU fuels in their context. The simplification of the net-zero-CO2-emission constraint may seem trivial or logical, but it does change and simplifies the discussion significantly by avoiding a very obvious question (how much CO2 does a CCU fuel really mitigate?). Furthermore, it allows one to compare CO2-based and CO2-free synthetic fuels in a quantitative manner under the same zero-carbon footprint constraint.

Supporting Information

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The Supporting Information is available free of charge on the ACS Publications website at DOI: 10.1021/acs.iecr.9b00880.

  • Additional remarks about the second-law efficiency analysis; waterfall diagrams of the power–methanol–power, power–ammonia–power, power–methane–propulsion, and power–ammonia–propulsion systems (PDF)

Terms & Conditions

Most electronic Supporting Information files are available without a subscription to ACS Web Editions. Such files may be downloaded by article for research use (if there is a public use license linked to the relevant article, that license may permit other uses). Permission may be obtained from ACS for other uses through requests via the RightsLink permission system: http://pubs.acs.org/page/copyright/permissions.html.

Author Information

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  • Corresponding Author
  • Authors
    • Daniel Sutter - Institute of Process Engineering, ETH Zurich, Sonneggstrasse 3, 8092 Zurich, Switzerland
    • Mijndert van der Spek - Institute of Process Engineering, ETH Zurich, Sonneggstrasse 3, 8092 Zurich, SwitzerlandOrcidhttp://orcid.org/0000-0002-3365-2289
  • Notes
    The authors declare no competing financial interest.

Abbreviations

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ASU

air separation unit

BECC

bioenergy and CO2 capture

CCS

CO2 capture and storage

CCU

CO2 capture and utilization

CNG

compressed natural gas

DAC

direct air capture (of CO2)

DACCS

direct air capture and CO2 storage

DMFC

direct methanol fuel cell

GTCC

gas turbine combined cycle

ICE

internal combustion engine

LCA

life cycle analysis

LHV

lower heating value

MeOH

methanol

OCGT

open cycle gas turbine

PCC

postcombustion capture (of CO2)

PEM

polymer electrolyte membrane

PEMFC

polymer electrolyte membrane fuel cell

RE

renewable electricity

SOFC

solid oxide fuel cell

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  • Abstract

    Figure 1

    Figure 1. Representation of possible technology chains yielding linear or circular economies, in a net-positive, net-zero, or net-negative CO2-emission system. (16,23) The representation includes fossil-based systems, CCU-fuel-based systems, and bioenergy-based systems. Process units include conventional postcombustion CO2 capture; direct capture of CO2 from air (DAC, requiring C-free renewable energy to operate); biomass conversion plants; CO2 conversion, including an electrolyzer for H2 generation and a collector of C-free renewable electricity (the stylized yellow spark). Arrows represent material fluxes (equipped with storage capacity) of fossil (from the subsurface, red), synthetic (from a conversion plant, blue), biogenic (from biomass, green), or oxidized (CO2, dark gray) carbon. The ultimate CO2 fate can be either release to the atmosphere (light gray cloud) or storage in the subsurface (stylized anticline aquifer).

    Figure 2

    Figure 2. Block diagram of the power–fuel–power systems investigated: (a) hydrogen, (b) methane, (c) methanol, and (d) ammonia. The blocks include their corresponding pressure levels, energy efficiency, and second-law (exergy) efficiency, and CO2 capture rate in the case of the power plants. The systems’ cyclic efficiency is given in the upper left corners. The supply of electricity to the fuel synthesis and to the DAC/N2-separation units is not represented in the figure for the sake of clarity. For methanol, the source of the CO2 and H2O emissions is the combustion of a purge stream containing CO2 and CO. In the case of methane, the water is a byproduct of the Sabatier reaction and the CO2 is part of the unreacted feed. These are minor streams but are included in the figure for completeness. The abbreviated fuel-to-power conversion plants are hydrogen solid oxide fuel cell (H2SOFC) and gas turbine combined cycle (GTCC). See Figure 3 for the corresponding power–fuel–propulsion chains.

    Figure 3

    Figure 3. Block diagram of the four power–fuel–propulsion systems investigated: (a) hydrogen, (b) methane, (c) methanol, and (d) ammonia. The blocks include their corresponding pressure levels, energy efficiency, and second-law (exergy) efficiency and CO2 capture rate in the case of the power plants. The systems’ cyclic efficiency is given in the upper left corners. The supply of electricity to the fuel synthesis and to the DAC/N2-separation units is not represented in the figure for the sake of clarity. The pressure indicated in the final conversion blocks represents the vehicle’s tank. For methanol, the source of the CO2 and H2O emissions is the combustion of a purge stream containing CO2 and CO. In the case of methane, the water is a byproduct of the Sabatier reaction and the CO2 is part of the unreacted feed. These are minor streams but are included in the figure for completeness. The abbreviated fuel-to-propulsion technologies are hydrogen polymer electrolyte membrane fuel cell (H2PEMFC), internal combustion engine (ICE), and direct methanol fuel cell (DMFC).

    Figure 4

    Figure 4. Waterfall diagrams of power–methane–power (a) and power–methanol–propulsion (b).

    Figure 5

    Figure 5. Breakdown of primary renewable power losses and resulting cycle efficiencies to produce 1 GW of power and/or propulsion (using DAC for the CCU fuel systems). The darkest color represents the relative energy output of each chain. H2 compression occurs only in the hydrogen for propulsion chain, where additional compression is required after electrolysis. “Air separation” indicates the efficiency loss related to DAC for the CCU fuels and to N2 separation for ammonia. “Air separation” and “fuel synthesis” do not occur in the hydrogen chains. Of the chemical energy carriers, hydrogen has the highest cycle efficiency, especially when providing propulsion in a transport application. The biggest losses are incurred in all systems in the electrolysis and fuel combustion steps, not in the fuel synthesis step. For the CCU propulsion cases, these losses are complemented with a large loss for direct air capture of CO2.

    Figure 6

    Figure 6. Comparison of the second-law efficiency of each system block and of its contribution to the efficiency loss for the power–fuel–power systems. The graph shows that the synthesis step of the synthetic fuels is already highly efficient, as shown by the high second-law efficiency. Fuel synthesis however has only a small impact on the cyclic efficiency loss over the overall system. Electrolysis and fuel combustion in a GTCC (with or without CCS) contribute much more to the overall cyclic efficiency loss, and they still exhibit quite some room for efficiency improvement, especially fuel combustion. DAC shows the highest potential for second-law improvement but has the lowest contribution to the cyclic efficiency loss.

    Figure 7

    Figure 7. Sensitivity of net system efficiency to changes in electrolysis, DAC/ASU, fuel synthesis, and fuel conversion. The second column from the left indicates how the input parameters were varied, represented on a 0–100% scale where possible. The resulting range of chain efficiencies is reported on the right with the middle line representing the base case. The input parameter assumptions are given as efficiency for electrolysis and final conversion and as an energy requirement for DAC/ASU. For fuel synthesis, see the corresponding text.

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