Optimizing industrial Energy: An Eco-Efficient system for integrated Power, Oxygen, and methanol production using coke plant waste heat and electrolysis

Abstract

This research presents a novel, eco-efficient hybrid system designed for the simultaneous production of power, oxygen, and methanol. It utilizes energy from coke plants and incorporates state-of-the-art waste heat recovery processes (WHRPs). The system effectively merges electricity and methanol production with WHRPs, improving both environmental sustainability and economic feasibility in industrial energy transformation. It consists of a fuel reforming and combustion unit, a waste heat recovery unit, a unit for hydrogen gas production through water electrolysis, and a methanol synthesis module. This configuration enables the production of 12.72 MW of electricity, 0.51 kg/s of oxygen, and 0.53 kg/s of methanol, achieving an energy productivity of 46.8 % and an exergy efficiency of 85.13 %. The economic analysis indicates competitive costs of $0.099 per kWh for electricity and $0.56 per kg for methanol. The system surpasses current technologies in thermodynamic efficiency, operational and product costs, and reduced CO2 emissions, demonstrating its potential as a sustainable and economically sound solution for industrial energy challenges. It supports global sustainability initiatives and fits within the circular economy concept.