Concept design, technical performance, and GHG emissions analysis of petroleum coke direct chemical looping hydrogen highly integrated with gasification for methanol production process

Abstract

Petroleum coke gasification for methanol production process has excellent application prospects for the clean utilization of high‑sulfur coke while limiting pollutant emissions from coke combustion. However, the process still suffers from high-energy use and a large CO2 generation caused by composition adjustment. This study proposes a novel petroleum coke chemical looping hydrogen-assisted gasification process for methanol production. Mass-energy coupling is realized by replacing the water gas shift unit with the chemical looping hydrogen unit, and the high temperature gasified gas heats the fuel reactor and in turn the feedstock. Two chemical looping hydrogen scenarios with an operating pressure of 3.0 and 0.1 MPa are considered. The methanol exergy can be increased from 484 to 1030 and 1028 MW by doubling the petroleum coke consumption through the chemical looping integration. The exergy efficiency of the new process is correspondingly increased from 51.6 to 57.1 and 55.2 % with 63.02 and 63.71 % reductions in direct CO2 emissions, as compared to the only gasification route. The calculated life cycle energy consumption and greenhouse gases emissions of the new processes are 40.02/43.84 GJ/t and 693/1055 kg CO2 eq/t, 15.14/7.05 % and 49.09/22.45 % lower than that of the benchmark process. The integration of high-pressure chemical looping technology can introduce significant technical and environmental benefits for methanol production from the petroleum coke.