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An integrated pinch analysis framework for the development of a low carbon dioxide emissions industrial site planning which includes a fuel cell configuration
Author(s)
John, Joe Mammen
Date Issued
2023
Type
Thesis
Publisher
Cape Peninsula University of Technology
Abstract
The proliferation of anthropogenic greenhouse gases, of which carbon dioxide is a major
constituent, has been the major driver of climate change. South Africa is one of the highest
greenhouse gas emitting countries mainly caused by increased industrialisation. Industrial
sites in South Africa have been clustered in industrial zones to keep toxic emissions away
from residential sites. This zonal planning inadvertently created zones of high carbon
dioxide concentration. The South African government has committed to sustaining the
national greenhouse gas emissions at a reasonably moderate value of below the 398-440
million tonnes of CO2 equivalent by 2030 as its contribution to lowering the global carbon
dioxide emissions. To control the emissions emanating from industrial zones, industrial
planners make use of an evaluation framework that accounts for the carbon footprint
associated with a particular industrial zone. The existing framework focuses on greenfield
sites (new planning sites), and is thus ill-adapted to brownfield sites (existing sites). This
study proposes a four-stage carbon dioxide lowering framework that industrial site
managers of brown-field sites could use to lower the carbon dioxide footprint of industrial
sites. This work extends the current systematic framework for low carbon dioxide industrial
site planning framework for a greenfield site, by proposing an alternative carbon dioxidelowering
sequential framework for a brownfield site.
The framework includes: 1. A baseline study to analyse the current carbon dioxide footprint
of an industrial site. 2. 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 carbonneutral
power for the hybrid power system while utilising methanol, a carbon dioxide
mineralised product. 3. The Total Sites Heat Integration technique to integrate the energy
produced in the site could be integrated to reduce external utilities required. 4. The Power
Pinch Analysis technique to optimise power distribution from the hybrid power system hub.
The study also proposes the option of introducing a subsidiary industry that includes carbon
dioxide mineralisation plants to chemically store the captured carbon dioxide. This is
because, in water-stressed South Africa, the viability of the geological storage of carbon
dioxide has not been considered because of the high probability of contamination of the
large water basin that is used to supplement the surface water resource. The challenge can
be overcome by increasing the value of carbon dioxide emissions by creating subsidiary industries that can utilise carbon dioxide as raw material and producing other value-added
products that can be utilised within the industrial site.
This study used an illustrative example to extend the current systematic framework for low
carbon dioxide industrial site planning framework used for greenfield site, by introducing an
alternative four-stage carbon dioxide-lowering sequential framework for a brownfield site. it
was determined that there are three possible opportunities to capture carbon dioxide from
stationary. The baseline study included scoping for thermal data, which included the target
temperature, supply temperature and specific heat capacity of the streams. The data
scoped by the site planner also include the power required and possible power that could
be generated within the site.
The study conducted a techno-economic investigation of the feasibility of including
subsidiary plants producing methanol, calcium carbonate and baking soda from the carbon
dioxide captured from the flue gas in the industrial site. This study included the cost of
capturing carbon dioxide from selected plants within the industrial site and determined the
operating and capital cost required using a bottom-up approach from mass balances. 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 cost of producing methanol and calcium carbonate
would only be sustainable if the price of raw materials such as hydrogen and wollastonite
could be brought down by producing hydrogen through solar-chemical water splitting and
the wollastonite from steelmaking slag. Baking production was determined to be the most
sustainable subsidiary industry in the carbon capture and utilisation framework with an
annual rate of return on investment of 12%.
The Total Site Heat Integration was applied for the evaluation, generation, optimisation and
usage of energy within the industrial site. it was determined that heat utility saving of
79.95% for the participating industries could be achieved for the industrial site. However,
the rate of return is for the Total site Heat integration (TSHI) was a low return of 8.98%. But,
since the main aim of the project is to reduce the carbon footprint and this rate of return
could be improved by the carbon tax rebate incentives for the carbon dioxide reduction
project
It was determined that solar and biomass energy were the two viable renewable sources of
power that could be used for the illustrative example. The inclusion of a direct methanol fuel cell configuration to the renewable energy mix was important to the site because it
generated clean carbon-neutral power for the hybrid power system while utilising methanol
produced by the subsidiary industry. Power Pinch Analysis was applied for the distribution
of the Hybrid Power System to the existing plant, and to the new subsidiary industry. 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 was 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.
constituent, has been the major driver of climate change. South Africa is one of the highest
greenhouse gas emitting countries mainly caused by increased industrialisation. Industrial
sites in South Africa have been clustered in industrial zones to keep toxic emissions away
from residential sites. This zonal planning inadvertently created zones of high carbon
dioxide concentration. The South African government has committed to sustaining the
national greenhouse gas emissions at a reasonably moderate value of below the 398-440
million tonnes of CO2 equivalent by 2030 as its contribution to lowering the global carbon
dioxide emissions. To control the emissions emanating from industrial zones, industrial
planners make use of an evaluation framework that accounts for the carbon footprint
associated with a particular industrial zone. The existing framework focuses on greenfield
sites (new planning sites), and is thus ill-adapted to brownfield sites (existing sites). This
study proposes a four-stage carbon dioxide lowering framework that industrial site
managers of brown-field sites could use to lower the carbon dioxide footprint of industrial
sites. This work extends the current systematic framework for low carbon dioxide industrial
site planning framework for a greenfield site, by proposing an alternative carbon dioxidelowering
sequential framework for a brownfield site.
The framework includes: 1. A baseline study to analyse the current carbon dioxide footprint
of an industrial site. 2. 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 carbonneutral
power for the hybrid power system while utilising methanol, a carbon dioxide
mineralised product. 3. The Total Sites Heat Integration technique to integrate the energy
produced in the site could be integrated to reduce external utilities required. 4. The Power
Pinch Analysis technique to optimise power distribution from the hybrid power system hub.
The study also proposes the option of introducing a subsidiary industry that includes carbon
dioxide mineralisation plants to chemically store the captured carbon dioxide. This is
because, in water-stressed South Africa, the viability of the geological storage of carbon
dioxide has not been considered because of the high probability of contamination of the
large water basin that is used to supplement the surface water resource. The challenge can
be overcome by increasing the value of carbon dioxide emissions by creating subsidiary industries that can utilise carbon dioxide as raw material and producing other value-added
products that can be utilised within the industrial site.
This study used an illustrative example to extend the current systematic framework for low
carbon dioxide industrial site planning framework used for greenfield site, by introducing an
alternative four-stage carbon dioxide-lowering sequential framework for a brownfield site. it
was determined that there are three possible opportunities to capture carbon dioxide from
stationary. The baseline study included scoping for thermal data, which included the target
temperature, supply temperature and specific heat capacity of the streams. The data
scoped by the site planner also include the power required and possible power that could
be generated within the site.
The study conducted a techno-economic investigation of the feasibility of including
subsidiary plants producing methanol, calcium carbonate and baking soda from the carbon
dioxide captured from the flue gas in the industrial site. This study included the cost of
capturing carbon dioxide from selected plants within the industrial site and determined the
operating and capital cost required using a bottom-up approach from mass balances. 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 cost of producing methanol and calcium carbonate
would only be sustainable if the price of raw materials such as hydrogen and wollastonite
could be brought down by producing hydrogen through solar-chemical water splitting and
the wollastonite from steelmaking slag. Baking production was determined to be the most
sustainable subsidiary industry in the carbon capture and utilisation framework with an
annual rate of return on investment of 12%.
The Total Site Heat Integration was applied for the evaluation, generation, optimisation and
usage of energy within the industrial site. it was determined that heat utility saving of
79.95% for the participating industries could be achieved for the industrial site. However,
the rate of return is for the Total site Heat integration (TSHI) was a low return of 8.98%. But,
since the main aim of the project is to reduce the carbon footprint and this rate of return
could be improved by the carbon tax rebate incentives for the carbon dioxide reduction
project
It was determined that solar and biomass energy were the two viable renewable sources of
power that could be used for the illustrative example. The inclusion of a direct methanol fuel cell configuration to the renewable energy mix was important to the site because it
generated clean carbon-neutral power for the hybrid power system while utilising methanol
produced by the subsidiary industry. Power Pinch Analysis was applied for the distribution
of the Hybrid Power System to the existing plant, and to the new subsidiary industry. 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 was 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.
Additional information
Thesis (DEng (Chemical Engineering))--Cape Peninsula University of Technology, 2023
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