A comprehensive carbon dioxide reduction framework for industrial site using pinch analysis tools with a fuel cell configuration

Abstract

Removing anthropogenic carbon dioxide emissions from existing industrial sites is essential to slow down climate change. A multipronged approach is required to reduce the carbon dioxide footprint of an existing industrial site by including carbon dioxide capture and utilisation, industrial symbiosis, heat integration and the introduction of renewable power sources. This work extends the current systematic framework for low carbon dioxide industrial site planning by proposing an alternative carbon dioxide lowering sequential framework for existing high carbon dioxide footprint industrial sites. The sequential framework will set out a four-step process using a suite of optimisation tools to guide industrial site managers to lower the carbon dioxide footprint of an existing industrial site that also features a fuel cell configuration. The framework includes a baseline study to analyse the current carbon dioxide footprint of the industrial site. The study then proposes a carbon capture and utilisation step to collate the carbon dioxide captured for chemical mineralisation for in-situ utilisation. The inclusion of the Direct Methanol Fuel Cell configuration is important to the site because it generates clean carbon-neutral power to the hybrid power system while utilising methanol, a carbon dioxide mineralised product. The following steps involve using Pinch Analysis tools to optimise the energy usage and renewable power usage within the industrial site. The energy produced at the site would be integrated to reduce external utilities required by using the Total Sites Heat Integration technique. The Power Pinch Analysis technique optimises power distribution from the hybrid power system hub. The illustrative case study is a typical industrial site in the Western Cape province in South Africa. It was determined that a potential 105 ton/day of carbon dioxide could be captured from the flue gas from industries on the site. The overall heat utility saving of 79.95% of the hot utility requirements for the participating industries in the site. It was also determined that the renewable sources of power which incorporated the fuel cell configuration would be sufficient to provide carbon-neutral power to the industrial site. The rate of return on the investment of the hybrid power system is found to be 20.68%. The carbon dioxide lowering framework for existing industrial sites could provide a sustainable, impactful guide for site planners to assist the country’s commitment to limit greenhouse gas emissions.