Reactive capture - the integration of carbon dioxide (CO2) capture and upgrade - bypasses the energy-intensive CO2 regeneration step and thereby offers potential to reduce both capital and energy costs. Alkali hydroxide solutions are a common type of capture solution for reactive capture, wherein CO2 is chemically absorbed in the form of carbonate and/or bicarbonate. The composition and pH of the post-capture solution depend on the CO2 concentration of the CO2 source used and the capture duration. Lower pH levels yield higher bicarbonate concentrations, facilitating greater CO2 release during the reactive capture step and resulting in enhanced electrolysis performance. For example, direct electrochemical reduction of a pure carbonate solution (pH~12.2) has a theoretical carbon monoxide (CO) Faradaic efficiency (FE) cap at 50%, but no cap exists for a pure bicarbonate solution (pH~8.2), leading to better electrolysis performance and lower operating expenditures (OPEX) for the capture and conversion cycle. However, achieving a low pH post-capture solution with higher bicarbonate content slows the capture rate, necessitating either a bigger contactor or longer capture time, thereby increasing capital expenditures (CAPEX) for the capture step. Using a silver catalyst, we report here the electrolysis energy efficiency (EE) of CO2 to CO using a 2M potassium hydroxide solution with a post-capture pH ranging from 13.5 (hydroxide and carbonate mix) to 8.2 (pure bicarbonate). We conducted a technical-economic analysis (TEA) to assess the CAPEX and OPEX of an industrial-scale reactive capture plant that captures both point source (10%) and atmospheric (420 ppm) CO2 using 2M potassium hydroxide with different post-capture pH values. The TEA includes a sensitivity analysis to account for improvements in electrolysis performance and reduced costs due to technological advancement and economies of scale in the future. Our results demonstrate that there is an optimal post-capture pH for potassium hydroxide-based reactive capture that balances the capture cost and electrolysis performance. This study serves as a guideline for choosing an industrial relevant pH to work with for future hydroxide-based reactive capture research.
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