Integrated water electrolysis is a core principle of new process configurations for decarbonized heavy industries. Water electrolysis generates H₂ and O₂ and involves an exchange of thermal energy. In this manuscript, we investigate specific traditional heavy industrial processes that have previously been performed in nitrogen-rich air environments. We show that the individual process streams may be holistically integrated to establish new decarbonized industrial processes. In new process configurations, CO₂ capture is facilitated by avoiding inert gases in reactant streams. The primary energy required to drive electrolysis may be obtained from emerging renewable power sources (wind, solar, etc.) which have enjoyed substantial industrial development and cost reductions over the last decade. The new industrial designs uniquely harmonize the intermittency of renewable energy, allowing chemical energy storage. We show that fully integrated electrolysis promotes the viability of decarbonized industrial processes. Specifically, new process designs uniquely exploit intermittent renewable energy for CO₂ conversion, enabling thermal integration, H₂ and O₂ utilization, and sub-process harmonization for economic feasibility. The new designs are increasingly viable for decarbonizing ferric iron reduction, municipal waste incineration, biomass gasification, fermentation, pulp production, biogas upgrading, and calcination, and are an essential step forward in reducing anthropogenic CO₂ emissions.

A standard CO₂ capture process is implemented in Aspen HYSYS, simulated, and evaluated based on available data from Fortum’s waste burning facility at Klemetsrud in Norway. Since amine-based CO₂ removal has high costs, the main aim is cost-optimizing. A simplified carbon-capture unit with a 20-m absorber packing height, 90% CO₂ removal efficiency, and a minimum approach temperature for the lean/rich amine heat exchanger (ΔT_min) of 10 °C was considered the base case simulation model. A sensitivity analysis was performed to optimize these parameters. For the base case study, CO₂ captured cost was calculated as 37.5 EUR/t. When the sensitivity analysis changes the size, the Power Law method adjusts the equipment cost. A comparison of the Enhanced Detailed Factor (EDF) and the Power Law approach was performed for all simulations to evaluate the uncertainties in the findings from the Power Law method. The optimums calculated for ΔT_min and CO₂ capture rate were 15 °C and 87% for both methods, with CO₂ removal costs of 37 EUR/t CO₂ and 36.7 EUR/t CO₂, respectively. With 19 m of packing height to absorber, the minimum CO₂ capture cost was calculated as 37.3 EUR/t and 37.1 EUR/t for the EDF and Power Law methods, respectively. Since there was a difference between the Power Law method and the EDF method, a size factor exponent derivation was performed. The derivation resulted in the following exponents: for the lean heat exchanger 0.74, for the lean/rich heat exchanger 1.03, for the condenser 0.68, for the reboiler 0.92, for the pump 0.88, and for the fan 0.23.

This study presents measured density and viscosity of N-methyldiethanolamine (MDEA) + H₂O, Dimethylethanolamine (DMEA) + H₂O, and Diethylethanolamine (DEEA) + H₂O mixtures. The density was measured at amine mass fraction w₁ from 0.3 to 1 for the temperature range 293.15–353.15 K. The excess molar volumes V^E were determined from density data. Redlich–Kister type polynomials were proposed to fit V^E and density deviation ln(ρ_γ) to represent measured densities. The viscosity was measured at amine mass fraction w₁ from 0.3 to 1 for the temperature range 293.15–363.15 K. The viscosity deviation η^E and excess free energy of activation for viscous flow ΔG^E* were determined from measured viscosities and examined for intermolecular interactions among mixture molecules. Correlations were proposed to fit viscosity data with acceptable accuracies. The McAllister’s three-body model was adopted to fit kinematic viscosities determined from density and dynamic viscosity data. The results showed the importance of examining intermolecular interactions that are discussed in McAllister’s four-body model to improve the accuracies of data fits.

We examined the cost implications of selecting six different types of heat exchangers as the lean/rich heat exchanger in an amine-based CO₂ capture process. The difference in total capital cost between different capture plant scenarios due to the different costs of the heat exchangers used as the lean/rich heat exchanger, in each case, is in millions of Euros. The gasketed-plate heat exchanger (G-PHE) saves significant space, and it saves considerable costs. Selecting the G-PHE instead of the shell and tube heat exchangers (STHXs) will save €33 million–€39 million in total capital cost (CAPEX), depending on the type of STHX. About €43 million and €2 million in total installed costs (CAPEX) can be saved if the G-PHE is selected instead of the finned double-pipe heat exchanger (FDP-HX) or welded-plate heat exchanger, respectively. The savings in total annual cost is also in millions of Euros/year. Capture costs of €5/tCO₂–€6/tCO₂ can be saved by replacing conventional STHXs with the G-PHE, and over €6/tCO₂ in the case of the FDP-HX. This is significant, and it indicates the importance of clearly stating the exact type and not just the broad classification of heat exchanger used as lean/rich heat exchanger. This is required for cost estimates to be as accurate as possible and allow for appropriate comparisons with other studies. Therefore, the gasketed-plate heat exchanger is recommended to save substantial costs. The CO₂ capture costs of all scenarios are most sensitive to the steam cost. The plate and frame heat exchangers (PHEs) scenario’s capture cost can decline from about €77/tCO₂ to €59/tCO₂ or rise to €95/tCO₂.

The performance of a plate heat exchanger (PHE), in comparison with the conventional shell and tube types, through a trade-off analysis of energy cost and capital cost resulting from different temperature approaches in the cross-exchanger of a solvent-based CO₂ capture process, was evaluated. The aim was to examine the cost reduction and CO₂ emission reduction potentials of the different heat exchangers. Each specific heat exchanger type was assumed for the cross-exchanger, the lean amine cooler and the cooler to cool the direct contact cooler’s circulation water. The study was conducted for flue gases from a natural-gas combined-cycle power plant and the Brevik cement plant in Norway. The standard and the lean vapour compression CO₂ absorption configurations were used for the study. The PHE outperformed the fixed tube sheet shell and tube heat exchanger (FTS-STHX) and the other STHXs economically and in emissions reduction. The optimal minimum temperature approach for the PHE cases based on CO₂ avoided cost were achieved at 4 °C to 7 °C. This is where the energy consumption and indirect emissions are relatively low. The lean vapour compression CO₂ capture process with optimum PHE achieved a 16% reduction in CO₂ avoided cost in the cement plant process. When the available excess heat for the production of steam for 50% CO₂ capture was considered together with the optimum PHE case of the lean vapour compression process, a cost reduction of about 34% was estimated. That is compared to a standard capture process with FTS-STHX without consideration of the excess heat. This highlights the importance of the waste heat at the Norcem cement plant. This study recommends the use of plate heat exchangers for the cross-heat exchanger (at 4–7 °C), lean amine cooler and the DCC unit’s circulation water cooler. To achieve the best possible CO₂ capture process economically and in respect of emissions reduction, it is imperative to perform energy cost and capital cost trade-off analysis based on different minimum temperature approaches.

This study presents the measured densities and viscosities of three ternary aqueous mixtures of tertiary and primary amines. The tertiary amines of n-methyldiethanolamine (MDEA), dimethylethanolamine (DMEA), diethylethanolamine (DEEA), and the primary amine monoethanolamine (MEA) at different concentrations (mass%) were mixed to prepare the liquid mixtures. The excess molar volume VE of the mixtures was analyzed using measured densities to acquire a better understanding of the molecular packing and intermolecular interactions in the mixtures. The excess free energy of activation ∆GE* and excess entropy of activation ∆SE* for viscous flow were determined from the measured viscosities by implementing the theory of rate processes of Eyring. Correlations based on the Redlich–Kister type polynomial were adopted to correlate the excess properties VE and ∆GE* as a function of the amine mole fraction and temperature. The results showed that the correlations were able to represent the measured data with satisfactory accuracies for engineering calculations.