Renewable Fuels of Non-Biological Origin (RFNBOs, a.ka. “eFuels”) are drop-in replacements for fossil fuels in the “hard-to-abate” sectors, and utilise existing distribution and storage infrastructure, but suffer from low synthetic efficiency. In particular, the low efficiency and high energy consumption of hydrogen synthesis by freshwater electrolysis remains a problem to be addressed. In the current study, we explore the potential of saltwater electrolysis (chloralkali) for the synthesis of eFuels generally, and specifically eMethanol. The study explores the use of chlorinated water in carbonate-loop pH-swing “cold capture” of carbon dioxide, and the resulting synergetic integration of the chloralkali process in eFuel syntheses. Doing so eliminates the high energy consumption of the calciner and the slaker of the benchmarked carbonate-loop thermal-swing method. It is replaced with a spontaneous chemical process in which chlorine is neutralized in the presence of carbonates. This allows the simultaneous solution of “The Chlorine Problem” of saltwater electrolysis, and a lower overall energy consumption of direct air capture when combined with green hydrogen synthesis. The only limitation on the comparison is that a large amount of carbon dioxide is over-captured when using chloralkali. That is, the ratio of hydrogen generated to carbon dioxide captured is fixed by the stoichiometry of chloralkali and not that of the eFuel. This results in an excess of carbon captured and thus a carbon-negative eFuel. We examine one configuration of secondary revenue and use it to inform the marginal cost of CO2 capture. In the system proposed by Aeon Blue Technologies (ABT), carbon dioxide is absorbed into caustic according to the standard method. Hydrogen gas is produced in a standard chloralkali electrolyzer, along with caustic for the contactor, and chlorine. Water oxidation by chlorine gives the strong acid, hydrochloric acid, and the weak acid, hypochlorous acid, which react directly with wet carbonate to release CO2. H2 and CO2 react in a methanol reactor to produce eFuel. H2 is the limiting reagent for eFuel synthesis, giving an excess of cold captured CO2. Thus, the current study underscores significant advancements in renewable fuel synthesis, particularly eMethanol, and evaluates the carbon capture and energy efficiency of a novel method. The simulation indicates that the marginal energy cost for a tonne of CO2 is ∼ 184kWh. This gives ∼ 76 % theoretical carbon capture efficiency and an overall process efficiency of 79.5 % (approximately a threefold improvement over the benchmark). The authors are unaware of a comparable method. The overall system yields a tonne of carbon-neutral e-methanol (eMeOH) while capturing an additional 3 tonnes of carbon dioxide, which means the modelled process captures over 300 % more carbon dioxide than is released upon combustion of the eFuel. In summary, this research contributes valuable insights into carbon-negative eFuel production, representing a significant scientific step in sustainable fuel production.
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