Industrial CO2 Emissions Research Articles

Study on steam energy efficiency enhancement, cost management and CO2 emissions in the food industry

Malaysia’s energy intensity per unit GDP has been increasing since the 1990s, leading to the government’s efforts to promote energy efficiency via policies and initiatives such as Energy Performance Contracting (EPC). Additionally, the industrial sector in Malaysia consumed 28% of total final energy in 2018, placing it as the country’s second-largest final energy consumer [1]. This case study focuses on improving energy efficiency in the steam system of an existing plant in the food industry in Malaysia. This work was performed in collaboration with a local Energy Service Company (ESCO) to study the existing steam system, recognize its process requirements and constraints and consequently propose and evaluate retrofit opportunities. These opportunities were evaluated across 3 performance parameters (power output or energy savings, cost savings and CO2 emissions savings). Simulations were performed using the Steam System Modeler Tool (SSMT). The study found that Combined Heat and Power (CHP) was not feasible due to a combination of low steam pressure and flowrate available in the system. However, the study also found that improving condensate recovery coupled with condensate flashing from the high pressure to low pressure header offered the highest increments in overall performance.

Preliminary investigation on spent garnet as a novel supplementary cementitious material

The escalating global demand for cement, a fundamental material in infrastructure development, has exacerbated environmental challenges, particularly through significant carbon dioxide (CO₂) emissions, which account for approximately 8.3 % of global anthropogenic CO₂ output. This research explores the potential of spent garnet powder, a byproduct of abrasive water jet machining, as a sustainable supplementary cementitious material (SCM) to mitigate these impacts. The spent garnet powder, characterized by a high concentration of silicon dioxide (SiO₂), aluminum oxide (Al₂O₃), and iron oxide (Fe₂O₃), was subjected to rigorous analysis. X-ray Fluorescence (XRF) confirmed its chemical suitability for pozzolanic applications, while laser particle size analysis revealed a finer granulometry relative to Ordinary Portland Cement (OPC), which is advantageous for enhancing pozzolanic reactivity. Scanning Electron Microscopy (SEM) demonstrated the angular and irregular morphology of the garnet particles, which is conducive to improved interfacial bonding within the cement matrix. X-ray Diffraction (XRD) identified active mineral phases that are critical for promoting pozzolanic reactions, and Thermogravimetric Analysis (TGA) demonstrated the material’s superior thermal stability, with minimal decomposition at elevated temperatures. Fourier Transform Infrared Spectroscopy (FTIR) identified strong silicon-oxygen (Si-O) and aluminum-oxygen (Al-O) bond structures, indicative of robust pozzolanic potential. The Strength Activity Index (SAI) and Frattini tests further substantiated the pozzolanic activity, revealing that a 10 % replacement of OPC with SGP not only enhances compressive strength but also meets the stringent requirements of ASTM C618. Additionally, the economic analysis underscores the cost-effectiveness of utilizing spent garnet powder, presenting a viable strategy for reducing both production costs and CO₂ emissions in the cement industry. This study conclusively positions spent garnet powder as a highly promising supplementary cementitious material, with significant implications for advancing sustainable construction practices and reducing the environmental footprint of cement production.

Effect of different calcination temperatures on clinker and hydration properties of solid waste-based calcium sulfoaluminate cement

Calcium sulfoaluminate (CSA) cement is a promising alternative to Portland cement for reducing CO2 emissions in the cement industry. In this study, solid-waste-based calcium sulfoaluminate cement (SWCSA) was synthesized from steel slag, phosphogypsum, carbide slag, and bauxite. The effects of calcination temperature (1190–1310 °C) on the properties of the SWCSA clinker before and after hydration were studied, and the hydration process was simulated. The main mineral phases of the clinker were C4A3S̅, C2S, and C4AF. During calcination, Fe³⁺ could replace Al3+ in C4A3S̅ to generate C4A3S̅-c. As the calcination temperature increased, the extent of Fe3+ substitution increased, resulting in more C4A3S̅-c, and the amount of C4AF decreased. The element distribution diagram shows the distribution of minor elements in different phases (such as Ti, Mg and K). In terms of physical properties, the SWCSA setting time was prolonged upon increasing the calcination temperature. Furthermore, SWCSA with the best 28 d compressive strength (89.7 MPa) was obtained at a low calcination temperature (1190 °C). During hydration, the initial SWCSA hydration rate was fast, a large amount of ettringite was generated, and the cumulative hydration heat was low. The ratio of the amount of ye'elimite consumed to the initial amount was positively correlated with the compressive strength. In addition, a relationship was observed between AFt/AH3 and the compressive strength. Overall, SWCSA could be prepared at a lower calcination temperature than conventional CSA, offering a new avenue for recycling industrial solid waste via a less-energy-intensive process to obtain high-performance cementitious materials.

Deciphering the CO2 hydrates formation dynamics in brine-saturated oceanic sediments using experimental and machine learning modelling approach

One of the potential strategies for limiting global warming is capturing excess amounts of industry CO2 emissions and sequestrating it inside the oceanic sediments as CO2 hydrates. The seabed consists of sediments with different porosity and sizes, which can significantly impede the kinetics of CO2 hydrates. To address these challenges, in this novel work the CO2 hydrate kinetics and morphologies have been investigated in brine-rich [3.5 wt% NaCl] coarse sediments [porosity = 0.28, Ø =0.5-1.5 mm], granule sediments [porosity = 0.43, Ø =1.5-3 mm] and dual sediments [coarse + granules] inside a high-pressure reactor [3.5 MPa, 1-2 oC] with artificial seabed. According to the key experimental results, the water-to-hydrate conversion [%] was estimated to be 67.24 (± 3.02) % for coarse sediments, 49.58 (± 4.97) % for dual sediments (coarse + granules), and 27.68 (± 5.21) % for granules. In-situ Raman spectroscopy was used to evaluate the real-time solubility of CO2 [0.023 mol/mol], and image processing thresholding was used to identify CO2 hydrate distribution patterns. A mathematical model was proposed as a major contribution to predict CO2 hydrates kinetics in sediments, using 94,203 data points. The model was trained via a supervised machine-learning [ML] algorithm and can predict CO2 hydrate kinetics with an AARD of 7.54-8.47%.

Green slag cement with nano copper oxide and nano silica: Enhanced antimicrobial and structural properties

The global construction industry is facing challenges related to sustainability, environmental impact, and the demand for innovative materials with multifunctional properties. A major concern is the durability of cement structures, which is often compromised by harmful bacteria and algae. These microorganisms accelerate the deterioration of structures, increase maintenance costs, and pose safety risks. Addressing these issues is essential to prolong the life of cement-based structures and reduce their environmental and carbon footprint. Cement in moist environments is particularly vulnerable to microbial growth, leading to structural weaknesses and degradation. This degradation necessitates costly repairs, shortens the lifespan of infrastructure, creates a threat to human lives, and contributes to increased carbon emissions. To tackle these challenges, researchers have tried to develop low-carbon cement ((green cement) with antimicrobial properties. Nanomaterials like nano-copper oxide (nCuO) and nano-silica (nSiO₂) have shown great potential in enhancing both the structural performance and microbial resistance of green cement. When nanomaterials, nCuO is incorporated into Portland slag cement (PSC), which already has a lower carbon footprint compared to traditional cement, enhances antibacterial and antialgal properties but adversely impacts the mechanical performance and to counter the adverse effect of nCuO, nSiO2 added to improve the mechanic performance. PSC is known for its ability to reduce industrial waste and CO₂ emissions, and the addition of nCuO and nSiO₂ makes it an even higher-performance material. Effects of nCuO and nSiO₂ on PSC have been studied by using isothermal calorimetry to assess hydration kinetics, X-ray diffraction to observe composition changes during hydration, scanning electron microscopy (SEM) to analyze microstructural changes, and mechanical testing to evaluate the strength of the material. The effectiveness of antimicrobial properties is studied in lab and field experiments. The results revealed improved compressive strength and significant resistance to bacterial and algal growth. The combination of nCuO's antimicrobial properties and nSiO₂'s ability to enhance the cement's strength created a synergistic effect that optimizes both performance and durability. Additionally, the study proposed a model to better understand the interaction between these nanomaterials, offering valuable insights into the mechanisms of hydration and microbial inhibition.

CFD studies into frictional effects of ship coatings to enhance condition monitoring & increase efficiency

Abstract Managing biofouling on ship hulls is essential for reducing CO2 emissions in the shipping industry. Biofouling, characterized by the accumulation of organisms on hulls, escalates surface roughness and hydrodynamic drag, subsequently increasing fuel consumption and CO2 emissions. In response, AkzoNobel, Royal Philips, and Damen Shipyards are developing a fouling prevention technology that utilizes Ultra Violet Light Emitting Diodes (UV-LEDs). The use of an array of multiple UV-LED tiles may lead to non-uniformities from gaps between tiles, potentially increasing frictional resistance due to variations in thickness and surface roughness at the tile joints. This study examines the impact of these non-uniformities on skin friction through simulations using the commercial Computational Fluid Dynamics (CFD) software, Star-CCM+. The analysis highlights effective jointing methods that minimize drag forces by optimizing gap-filling techniques, thus comparing favourably to traditional coatings. The findings contribute significantly to advancing a UV-C hull fouling prevention system, promising reduced environmental impacts and enhanced operational efficiency in the shipping industry.

Carbon sequestration potential of tree planting in China

China’s large-scale tree planting programs are critical for achieving its carbon neutrality by 2060, but determining where and how to plant trees for maximum carbon sequestration has not been rigorously assessed. Here, we developed a comprehensive machine learning framework that integrates diverse environmental variables to quantify tree growth suitability and its relationship with tree numbers. Then, their correlations with biomass carbon stocks were robustly established. Carbon sink potentials were mapped in distinct tree-planting scenarios. Under one of them aligned with China’s ecosystem management policy, 44.7 billion trees could be planted, increasing forest stock by 9.6 ± 0.8 billion m³ and sequestering 5.9 ± 0.5 PgC equivalent to double China’s 2020 industrial CO2 emissions. We found that tree densification within existing forests is an economically viable and effective strategy and so it should be a priority in future large-scale planting programs.

Drying-Wetting Correlation Analysis of Chloride Transport Behavior and Mechanism in Calcium Sulphoaluminate Cement Concrete.

In response to rising CO2 emissions in the cement industry and the growing demand for durable offshore engineering materials, calcium sulphoaluminate (CSA) cement concrete, known for its lower carbon footprint and enhanced corrosion resistance compared to Ordinary Portland Cement (OPC), is increasingly important. However, the chloride transport behavior of CSA concrete in both laboratory and marine environments remains underexplored and controversial. Accordingly, the chloride ion transport behaviors and mechanisms of CSA concrete in laboratory-accelerated drying-wetting cyclic environments using NaCl solution and seawater, as well as in marine tidal environments, were characterized using the rapid chloride test (RCT), X-ray diffraction (XRD), mercury infiltration porosimetry (MIP), and thermogravimetric analysis (TGA). The results reveal that CSA concrete accumulates more chloride ions in NaCl solution than in seawater, with concentrations 2-3.5 times higher at the same water-cement ratio. Microscopic analysis indicates that calcium and sulfate ions present in seawater facilitate the regeneration of ettringite, thereby increasing the density of the surface pore structure. The hydration and repair mechanisms of CSA concrete under laboratory conditions closely resemble those in marine tidal conditions when exposed to seawater. Additionally, this study found that lower chloride ion concentrations and pH levels inhibit the formation of Friedel's salt. Therefore, laboratory experiments with seawater can effectively simulate CSA concrete's chloride transport properties in marine tidal environments, whereas NaCl solution does not accurately reflect actual marine conditions.

Testing the Environmental Kuznets Curve Hypothesis within the Context of Industrial Development through NARDL Model: The Case of France

Energy is one of the necessary and vital factors for the economic development of countries and the increase in living standards. The limited availability of conventional energy resources, in parallel with the rapid increase in energy consumption due to industrialization activities and technological developments, has encouraged countries to change their energy production policies and use alternative energy sources. For this purpose, in the study, the relationship and direction of the relationship between industrial production, CO2 emissions, energy use and economic growth in France are examined with the carrying out of the ADF, PP, KPSS unit root and the NARDL test for the period 1990–2023. The analysis findings reveal that the variables are cointegrated in the long-run and a 1% unit raise in energy consumption would trigger CO2 emissions by 0.46%. The increase in energy consumption in the long term affects both negatively and positively in the long term. While a 1% increase in energy consumption reduces carbon emissions by 0.48%, a 1% decrease causes a 0.35 decrease in carbon emissions. The positive increase in economic growth and the negative increase in energy consumption trigger environmental pollution by causing an increase in carbon dioxide emissions. There is interdependence between economic activities and environmental pollution. Policy makers need to adopt a strategic approach in solving the rapid industrialization phenomenon and the accompanying magnitude of energy consumption, the pressure on natural resources and the environmental pollution problems resulting from them. In this respect, it is an inevitable necessity for countries to continue multilateral negotiations in which the public sector, business world, academia and non-governmental organizations will take part in solving environmental problems.

Addressing small-scale temperature swing adsorption challenges using intensified fluidised bed technology for carbon capture process development

Polyethylenimine (PEI)-based adsorbents exhibit high CO2 capacities, making them potential candidates for mitigating unavoidable industrial CO2 emissions. However, desorption of CO2 from PEI, and from adsorbents in general, has received far less attention in the literature than adsorption. Whilst Temperature Swing Adsorption (TSA) is simple to conceptualise, it is difficult to implement in small-scale experiments in practice. Here we study the desorption characteristics of a commercial branched PEI adsorbent in a small-scale swirling fluidised bed reactor (TORBED) to improve the small-scale heat transfer rates. Our experimental results show that higher desorption temperatures, higher gas flow rates, and higher CO2 concentrations during adsorption can improve the desorption efficiency (defined as the amount of CO2 removed as a fraction of the initial amount adsorbed). In terms of kinetics, we found that the fractional order kinetic model provided the best fit to the PEI adsorbent, implying that this adsorbent involves multiple simultaneous molecular interactions, physisorption processes, and chemisorption processes, that cannot be described by simpler pseudo 1st or 2nd order models. Desorption rates in the TORBED in this study were 1 order of magnitude faster than fluidised beds, and 2–3 orders of magnitude faster than packed beds.

Towards green steel-energy and CO2 assessment of low carbon steelmaking via hydrogen based shaft furnace direct reduction process

Under current stringent climate policies, the iron and steel industry, as a major contributor to industrial CO2 emissions, urgently needs the development of low-carbon metallurgical technologies. This work focuses on the hydrogen-based shaft furnace process, which can utilize green energy to significantly reduce CO2 emissions. This work combines the hydrogen-based shaft furnace CFD model, regression equations, and Aspen Plus model to develop a multi-gas source DR (Direct Reduction) plant model. This combination significantly reduces computation time while maintaining predictive accuracy. The transformation from COG (Coke Oven Gas)-DR to H2-DR plant was studied, showing that the top gas circulation process greatly reduces the net carbon input of the entire DR plant. However, the energy consumption of electrolytic hydrogen production limits the transformation of COG-DR plant to H2-DR plant. The process CO2 emissions depend largely on electrical energy footprint. Under traditional electrical energy footprint, the CO2 emissions of H2-DR-EAF (Electric Arc Furnace) route are about four times those of the COG-DR-EAF route. Only when using green source energy does the H2-DR-EAF route achieve the lowest CO2 emissions among all routes, at 344 kg/tls, which is 79 % lower than that of the BF (Blast Furnace)-BOF (Basic Oxygen Furnace) route.

A Novel Approach for Predicting CO2 Emissions in the Building Industry Using a Hybrid Multi-Strategy Improved Particle Swarm Optimization–Long Short-Term Memory Model

The accurate prediction of carbon dioxide (CO2) emissions in the building industry can provide data support and theoretical insights for sustainable development. This study proposes a hybrid model for predicting CO2 emissions that combines a multi-strategy improved particle swarm optimization (MSPSO) algorithm with a long short-term memory (LSTM) model. Firstly, the particle swarm optimization (PSO) algorithm is enhanced by combining tent chaotic mapping, mutation for the least-fit particles, and a random perturbation strategy. Subsequently, the performance of the MSPSO algorithm is evaluated using a set of 23 internationally recognized test functions. Finally, the predictive performance of the MSPSO-LSTM hybrid model is assessed using data from the building industry in the Yangtze River Delta region as a case study. The results indicate that the coefficient of determination (R2) of the model reaches 0.9677, which is more than 10% higher than that of BP, LSTM, and CNN non-hybrid models and demonstrates significant advantages over PSO-LSTM, GWO-LSTM, and WOA-LSTM hybrid models. Additionally, the mean square error (MSE) of the model is 2445.6866 Mt, and the mean absolute error (MAE) is 4.1010 Mt, both significantly lower than those of the BP, LSTM, and CNN non-hybrid models. Overall, the MSPSO-LSTM hybrid model demonstrates high predictive accuracy for CO2 emissions in the building industry, offering robust support for the sustainable development of the industry.

The role of the iron and steel sector in achieving net zero U.S. CO2 emissions by 2050

The U.S. steel sector is a hard-to-abate sector because of its heavy dependence on fossil fuels and its high capital requirements. In 2015, the sector was one of the major carbon emitters, contributing 10 % of the U.S. industrial CO2 emissions. The ability to decarbonize the U.S. iron and steel sector directly affects the ability of the U.S. to achieve economy-wide net zero CO2 by 2050. In this paper, we use the Global Change Analysis Model (GCAM) to analyze different U.S. steel sector decarbonization pathways under varying technology, policy, and demand futures. These pathways provide insights on how various low-carbon steelmaking technologies such as those using carbon capture and storage (CCS), hydrogen, or scrap could help reduce U.S. steel emissions by mid-century. In our primary decarbonization pathway, we find that nearly all of the conventional fossil-based steelmaking capacity is fully integrated with CCS by 2050. However, without CCS availability, almost all of the conventional fossil-based steelmaking is phased-out by 2050 and is replaced by hydrogen-based production. Scrap-based production continues to remain vital across both of these decarbonization pathways. Furthermore, we find that demand reduction could help reduce the required levels of CCS and hydrogen-based production in the decarbonization pathways. Implementation of advanced energy efficiency measures could help substantially reduce the sector's energy usage. Finally, we observe that addressing the embodied carbon transfer associated with steel imports will be crucial for fully decarbonizing the U.S. steel sector.

Exploring enhanced CO2 separation from blast furnace gas: A multicolumn vacuum swing adsorption approach with process design and experimental assessment

Excessive emissions of carbon dioxide (CO2) are a major driver of global warming. Blast furnace gas (BFG) represents a major source of CO2 emissions in the steel industry, accounting for approximately 30 % CO2 emissions among the industry sectors. Hence, effective CO2 capture from BFG is imperative. This study presents an approach utilizing the vacuum swing adsorption (VSA) technology to capture CO2 from BFG. A 6-column VSA rig was designed and constructed to separate CO2 from a simulated BFG (CO2/N2 = 20 %/80 %) using zeolite 13X as adsorbents. The VSA process involved steps of adsorption, desorption, heavy product purge, light product re-pressurization, and pressure equalization. Five different process modes, i.e., 1-column and 3-step, 2-column and 6-step, 2-column and 8-step, 3-column and 9-step, and 4-column and 16-step configurations, were implemented to evaluate the influence of various process design factors on the separation performance. Additionally, a 6-column and 36-step process was devised to conduct a parametric study of VSA cycles by varying the adsorption duration and desorption pressure. Results revealed the pivotal role of heavy product purge and pressure equalization on the separation performance. The six-column process achieved a CO2 purity and recovery of 94 % and 82 %, respectively, with a energy consumption of 0.76 GJ/tonCO2 when employing a desorption step duration of 240 s and pressure of 8 kPa. In addition, a method of process optimization based on the bed capacity ratio, C, was introduced in this study, which provides a dimensionless quantity of the utilization of the adsorption column. Moreover, capturing CO2 from BFG through the VSA cycle not only enhances its heating value but also yields substantial advantages in terms of mitigating CO2 emissions.

Characterization of an additively manufactured coating using an upsetting test with miniaturized cylindrical specimen

In order to reduce CO2 emissions in production industry, the combination of several manufacturing processes is coming to the fore. One example is the combination of metal additive manufacturing with the forming technology, whereby the advantages of both process technologies can be used. The process combination can be applied to produce hybrid barrel sleeves, for example. Using a laser-based directed energy deposition (DED-LB/M), a circular coating is first applied to a blank, which is then deep-drawn in a second step. The additive layer serves as a wear-resistant coating. One way to increase process understanding for this process combination is numerical simulation. An important part of setting up the simulation model is characterizing the material in terms of its mechanical behavior. In order to avoid long building times, small sample geometries are suitable for characterizing the additive material. In the context of the paper, the upsetting test is therefore carried out with miniaturized specimens, whereby not only the base material Bainidur AM but also the addition of tungsten carbide microparticles and carbon nanoparticles is investigated. The in-situ modification of the material significantly increases the yield strength, but at the same time reduces the ductility. The microhardness of the material is also increased by the addition of carbon or tungsten carbide.

Pathways for the US food processing sector under economy-wide net zero in a multisector dynamic framework

The food processing sector is a large, energy-consuming and CO2-emitting industrial sector. The sector was estimated to account for 6 % of US industrial CO2 emissions in 2020. The sector uses significant amounts of fossil fuels, biomass, and electricity to perform a range of operations such as baking, drying, and refrigeration. Additionally, the sector is tightly linked to the agriculture and land use sectors. In this analysis, we use the Global Change Analysis Model (GCAM), a coupled, energy-economy-agriculture-land-use-water-climate systems model, to examine the role of the food processing sector in the EMF37 2050 US net-zero CO2 scenario. We explore the implications for technology and fuel choice and go beyond to examine US food consumption, food prices, and land-use change. To better understand the sensitivity of our results to alternative developments, we assess multiple sensitivity scenarios for the US and other world regions, with a focus on varied food processing energy intensity pathways.We find that along the EMF37 US net-zero path, the food processing sector electrifies the majority of its process heat. We also find that the industry phases-down natural gas use and completely phases-out coal. Additionally, we observe a marginal decrease in US food consumption per capita relative to our reference scenario. This primarily occurs due to the increase in consumer food prices resulting from increased demand for purpose-grown biomass crops, which compete with food crops for land resources. Finally, cumulative energy savings of 4.2 EJ are achieved from 2020 to 2050 in a scenario in which the US reduces its food processing intensity to EU-15 levels.

Electric Taxiing System. Kinetic Energy Recovery System as an Electric Taxiing Solution: Economic and environmental analysis: Phenom 300 case study

The aviation industry has thrived in recent years, with a significant increase in passenger numbers, leading to the development of larger aircraft fleets and the expansion of airport infrastructure. In 2019, more than 4.5 billion passengers traveled by airplane, which represents an 80% increase compared to 2009. As a consequence, this growth has also resulted in longer taxiing times for aircraft, increasing fuel consumption and operational costs. The industry's CO2 emissions have quadrupled since the 1960s, with over 1 billion tons released in 2019, contributing to global warming. Given that the improvements being made to current propulsion systems and the production of over 600 million liters of SAF (Sustainable Aviation Fuel) in 2023 do not seem sufficient to meet the ambitious goals set by regulators and operators, the logical solution would be to develop a system capable of moving the aircraft on the ground using alternative, cleaner, and cheaper energies, such as electric power. This paper explores the latest advancements in electric propulsion systems, specifically focusing on external and onboard systems. After the state of the art is established, this paper will cover a case study and propose a new alternative for an onboard system called ETS – Electric Taxiing System. The ETS is a 100% electric system for ground handling operations designed to use only the kinetic energy stored in a battery pack, which is recovered during aircraft landing and braking events. Although there are some studies on this topic, the author considers this paper to be more comprehensive as the results computed here take into account 96 variables, 60 simulations, several flight plans, and real-world data. The case study focuses on the implementation and dimensioning of the ETS, considering electric motor power and torque, and battery capacity for the Embraer Phenom 300. A brief economic and environmental analysis was also conducted, considering the operation of NetJets Europe, the world's leading and largest private jet company.

(Invited) Electrochemical Engineering Approaches for High-Performing Electrosynthesis of Polymer Precursors

The chemical industry accounts for ~5% of the US energy utilization and >30% of the US energy-derived industrial CO2 emissions. Amongst these processes, the production of organic chemical commodities, many of which are used as polymer precursors, account for the majority of the energy utilization (>1200 TBTU/y). The electrification of these processes via the implementation of electro-organic reactions could accelerate the decarbonization of the chemical industry, and bring additional sustainability advantages over their thermo-chemical counterparts. Currently, however, two major challenges prevent the deployment of electro-organic reactions: their low selectivity and their low production rates. To circumvent these barriers, our group deploys electrochemical reaction engineering principles to engineer electrode/electrolyte interfaces and design high-performing electro-organic processes. In this presentation, I will discuss how we implement this approach to understand and improve the performance of electro-organic reactions for the production of large-scale precursors for the production of Nylon 6,6 and polyethylene.The production of Nylon 6,6 involves the step-growth polymerization of 1,6-hexanediamine (HMDA) with adipic acid. HMDA is currently produced by the hydrogenation of adiponitrile (ADN). Here, I will present our insights into the electrohydrodimerization of acrylonitrile (AN) to adiponitrile (ADN). This is one of the largest electro-organic reaction deployed in industry and serves as a model process for the development of practical organic electrochemical processes. Our investigations on ADN uncovered relationships between the microenvironment at and near the electrical double layer (EDL) and reaction performance metrics (i.e., selectivity, efficiency, and productivity). I will discuss general guidelines for electrolyte formulation, dynamic electrochemical operation, the implementation of convective forces to mitigate transport limitations, ultimately leading in the conversion of AN to ADN at Faradaic efficiencies >80% and current densities of 100’s mA/cm2. Our learnings on ADN electrosynthesis helped us to engineer the electrocatalytic hydrogenation of ADN to HMDA, achieving the highest reported selectivity to date for this reaction (>95%). I will also show how similar electrochemical engineering approaches allowed us to elucidate factors that control performance in the electrochemical production of ADN from glutamic acid, an abundant and inexpensive bio-based feedstock, and of ethylene from bio-derived propionic acid. Through our studies, we aim to electrify and bring sustainability to chemical manufacturing, one reaction at a time.

A novel nanoparticles spilled-over In2O3 microcubes-enabled sustainable chemiresistor for environmental carbon dioxide monitoring

Achieving sustainable future energy goals includes enhancing renewable energy production, optimizing daily energy consumption using feedback loops and minimizing/monitoring contributions to atmospheric carbon dioxide (CO2). Developing economic next-generation CO2 sensors enables local monitoring of industrial CO2 emissions, aiding energy management and climate monitoring. This study elucidates the efficacy of CO2 chemiresistor based on indium oxide (In2O3) micro cubes with spilled-over nanoparticles. The investigation primarily focuses on fabricating and optimising In2O3-based CO2 chemiresistors utilizing a hydrothermal technique, creating porous micro cubes essential for enhanced CO2 monitoring. As revealed by various characterization techniques, the minimum crystallite size was found to be 24.92 nm with optimum porosity and a high surface-to-volume ratio comprising spilled-over nanoparticle morphology. The fabricated chemiresistor demonstrated excellent CO2 sensing efficacy with a maximum response of around 4.1% at room temperature with selectivity, repeatability, and reversible sensing behavior. The sensing mechanism has been revealed, which is supported by theoretical density functional theory evaluations. Notably, the sensing results reveal the capability of In2O3-based sensors to detect CO2 at low concentrations as low as ⩽10 ppm, which enables the chemiresistor for practical implementation in diverse sectors to achieve sustainability.

Environmental Performance of Ammonia Production in Indonesia using Life Cycle Assessment Approach

Ammonia is a fundamental component in fertilizer and chemical manufacturing processes around the world, but its production is a significant contributor to CO2 emissions in chemical industry. Implementation of carbon capture utilization and storage (CCUS) offers an alternative decarbonisation strategy to mitigate CO2 emissions in ammonia production. This study assesses the environmental performance of ammonia production through life cycle assessment (LCA) methodology. Environmental impacts are calculated using openLCA software with various impact assessment methods, including CML IA Baseline, Impact 2002+, Recipe 2016 Midpoint (H), and AWARE. The study scope encompasses the cradle-to-grave analysis, from the extraction of raw materials and transportation to ammonia production, main processes, distribution, and consumer product consumption, with a declared unit of 1-kg ammonia product. Our findings showed that CO2 removal and Power Plant in core processes in the core process as the most significant contributors to Global Warming Potential. Therefore, sensitivity analysis was conducted by reducing CO2 emission by 10% and 70% through CCUS implementation. The results showed that the CCUS implementation could reduce Global Warming Potential by up to 43%.