High-performance CO2 conversion
For industrial sites and more
Real Carbon Technology takes carbon capture and usage (CCU) to a new level. Our patent-protected solution offers direct CO2 and Hydrogen to methanol conversion faster and cheaper than traditional methods. We deliver multiple efficiency gains while saving on CAPEX and OPEX and bringing overall green methanol costs down.
and Storage (CCUS)
Capturing CO2 from industrial facilities, fossil or biomass-fueled power stations, or directly from the air.
Permanently storing CO2 in underground geological formations, onshore or offshore
Using captured CO2 as an input feed-stock to create products
CCUS is a group of technologies that contributes both to reducing emissions in key sectors directly and to removing CO2 to balance emissions that cannot be avoided – a critical part of net-zero goals.
The use of the CO2 for an industrial purpose can provide a revenue stream for CCUS facilities. Until now, the vast majority of CCUS projects have relied on revenues from the sale of CO2 to oil companies for enhanced oil recovery (EOR). But there are many other potential uses of the CO2, e.g. as a feed-stock for the production of synthetic fuels and chemicals.
We at RealCarbonTech focus on delivering the most efficient technology of turning carbon dioxide feed-stock into marketable methanol-based products for energy, chemical or transportation sectors.
FIT FOR INDUSTRY
Our technology can handle exhaust streams with low purity feed-stock making it of particular interest for heavy emitters who aim at meeting the CO2 reduction targets.
Reduced capital expenditures for the synthesis installations and operating costs of running shorter and simpler conversion process mature the technology while bringing product costs down even in smaller-scale projects.
EASY TO SCALE
Modular design allows efficient scalability of the synthesis installations in accordance with any available feed-stock volumes.
The process can use renewable power to produce methanol, that represents a stable way of storing low-carbon energy for easy transportation with already existing storage and distribution infrastructure.
It is generally known that production of methanol (MeOH) from biomass and from carbon dioxide and hydrogen does not involve experimental technologies. Almost identical proven and fully commercial technologies are used to make MeOH from fossil fuel-based syngas and can be used for renewable MeOH production.
Traditional MeOH synthesis technologies rely on low-pressure methods, which require complex production steps starting from feed-stock purification, turning it into synthesis gas, producing crude MeOH, separating it from water and other components and repeating the cycles multiple times to achieve desired process efficiencies.
With our method we eliminate the syngas phase achieving a direct conversion. We accept higher feed-stock impurities, which also reduces feed-stock conditioning and distillation phases. Where others use multiple reactors, compressors, columns, drums, boilers and etc., we achieve 95%+ CO2 conversion, 98% methanol selectivity and 95%+ methanol yield in a single step with a smaller reactor and a compressor.
Our know-how also delivers increased catalyst performance of up to 1:15 (15g of MeOH per 1g of catalyst) vs 1:1 in case of conventional methods.
Together with already available flue gases capture technologies our solution can be retrofitted into an existing facility, eliminating the need to redesign the plant’s processes while meeting emission reduction targets and extending asset useful lifetime in an economically attractive way.
At the same time our high-pressure method can be a value adding part to Power-to-Methanol projects with direct air capture systems reducing the final product costs through higher conversion efficiencies.
Methanol or, alternatively, dimethyl ether (DME) are the key products of our direct synthesis. Further downstream conversion to other methanol-based products is possible depending on the CCU project specifics and off-taking arrangements.
The solution for existing energy assets
Meeting net-zero goals requires tackling emissions across all energy sectors, including those that are labelled as “hard to abate”. This includes heavy industry (incl. cement, steel and chemicals production), which accounts for almost 20% of global CO2 emissions. Today’s industrial assets could generate more than 600 GtCO2 – almost two decade’s worth of current annual emissions – if they were to operate as they currently do until the end of their technical lives. Retrofitting CO2 capture and utilization equipment can enable the continued operation of existing plants, as well as associated infrastructure and supply chains, but with significantly reduced carbon foot-print.
Retrofitting facilities can also help to preserve employment and economic prosperity in regions that rely on emissions-intensive industry, while avoiding the economic and social disruption of early retirements.
Emitters < 1 mio tons of CO2/year
Emitters > 1 mio tons of CO2/year
The patent-protected direct methanol synthesis method has been developed and tested by A. Urakawa, Professor of Catalysis Engineering at Delft University of Technology (TU Delft), The Netherlands and his team.
Prof. Urakawa has a BSc degree in Applied Chemistry from Kyushu University (Japan) followed by MSc study in Chemical Engineering from TU Delft. After the PhD from ETH Zurich (Switzerland), and positions of Senior Scientist and Lecturer prof. Urakawa joined ICIQ, Spain in 2010. His research group combined fundamental as well as highly applied research and focus on rational development of heterogeneous catalysts and processes aided by in situ and operando spectroscopic methods. After nine years at ICIQ, Mr. Urakawa continues his research as a professor at TU Delft. Professor Urakawa is a recipient of Japan Society for the Promotion of Science Award 2020 and Japan Academy Medal 2021.
Headed by Mr. Tomasz Zmysłowski, Innox Nova sp. z o.o., Poland is the operational arm to commercialize the technology and make it available to a wide range of industrial facilities world-wide.
Innox Nova has been active in supporting industrial projects since 2013. Regional Innovative Leader of the Year 2010 and 2012 Mr. Zmysłowski is experienced in creating and implementing business platforms, connecting industrial partners and facilitating innovation clusters in Poland.
Together we have established an international team of experienced professionals from academia and business to make RealCarbonTech one of the leading technology providers globally.
Methanol is a key product in the chemical industry. It is mainly used for producing other chemicals such as formaldehyde, acetic acid and plastics. Methanol is also a versatile fuel that can be used in internal combustion engines, and in hybrid and fuel cell vehicles and vessels. Liquid at ambient temperature and pressures, it is straightforward to store, transport and distribute, making it compatible with existing distribution infrastructure and blending with conventional fuels to create high-performance and low-carbon fuels.
Around 100 million tonnes (Mt) of methanol are produced per annum, nearly all of it comes from fossil fuels (either natural gas or coal). Only about 0.2 Mt of renewable methanol is produced annually. Renewable methanol can be made from a variety of sustainable feed-stocks, such as biomass, waste or CO2 and hydrogen.
Its use in place of fossil fuels will reduce greenhouse gas (GHG) emissions and in some cases can also reduce other harmful emissions (sulphur oxides [SOx], nitrogen oxides [NOx], and particulate matter [PM]).
Renewable methanol vs alternatives
Methanol has a number of advantages compared to some other proposed renewable energy carriers, including hydrogen, LNG, ammonia and batteries.
Hydrogen gas has been proposed as an energy storage medium and produces, besides energy, only water when combusted. In practice, however, because of its low volumetric density hydrogen requires either compression to high pressures (350-700 bar) or liquefaction at very low temperature (-253°C), making its storage problematic and energy-intensive. It is also highly flammable and explosive and can diffuse through many commonly used metals and materials. The infrastructure needed to transport, store and dispense hydrogen safely would therefore be very expensive.
LNG too requires cryogenic temperatures for its storage (-162°C). If the space for the containment is included in the comparison, the energy density of methanol is comparable to that of LNG.
Liquid ammonia has either to be cooled down to -34°C or kept under moderate pressure.
Methanol, on the other hand, does not need any refrigeration or pressurization because it is a liquid under ambient conditions.
The volumetric energy density of methanol is only about half that of gasoline and diesel, but about three times higher than compressed H2 (700 bar) and two times higher than liquid H2. One litre of methanol actually contains more hydrogen than one litre of liquefied H2.
An often-proposed purely hydrogen-based economy would require massive investment, and the construction of a costly and specialized infrastructure that does not exist presently.
As a liquid fuel, methanol is relatively easy to handle and does not need highly specialized equipment for its transport, storage and distribution. With minor and inexpensive modifications, the current infrastructure can be adapted to methanol, enabling a smooth transition to the use of renewable methanol.
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