Sustainable Syngas

Roadmap Overview

Synthesis gas (Syngas)—a mixture of carbon monoxide (CO), hydrogen (H₂), and hydrocarbon compounds—plays a crucial role in the sustainable production of fuels used for transportation and the manufacturing of plastics. Over the years, various feedstocks have been explored to improve syngas production in terms of carbon intensity and energy efficiency.

This roadmap focuses on the production of syngas using the electrolysis of water powered by renewable energy sources such as wind, solar, or hydropower. Electrolysis splits water (H₂O) molecules into hydrogen (H₂) and oxygen (O₂). The hydrogen produced through this process combines with captured carbon dioxide (CO₂) to form carbon monoxide (CO), hydrogen (H₂), and hydrocarbon compounds. These reactions take place in two key stages:

1. Electrolysis Chamber: The process begins with water electrolysis, where electricity from renewable sources splits water into hydrogen and oxygen.

2. Reactor Chamber: In the reactor, the CO₂ feedstock is heated and reacts with the hydrogen from electrolysis in the presence of a catalyst. This process forms syngas (CO and H₂), which can be used for fuel production.

Carbon capture technology is an essential component of this system. CO₂ is captured from industrial emissions, the atmosphere, or other sources using carbon capture, utilization, and storage (CCUS) technologies. The captured CO₂ is then processed and used to react with hydrogen to produce syngas. To ensure sustainability, the system requires a constant and reliable supply of CO₂, which is achieved through advanced capture and transportation methods.

Reference Case The reference case for this technology is based on Power-to-X (P2X) solutions, where renewable electricity is converted into carbon-neutral fuels or chemicals. This approach has been applied in various pilot projects aiming to produce synthetic fuels and chemicals for industries such as transportation, plastics, and energy storage.

Key Features: a. Renewable Energy Integration: The electrolysis process is powered by clean energy sources (e.g., wind, solar, or hydro), minimizing the carbon footprint. b. Carbon Capture Utilization: CO₂ captured from the atmosphere or industrial processes is used to produce syngas, ensuring a closed carbon cycle. c. Catalyst Efficiency: The reactor employs catalysts that increase the reaction rate between hydrogen and CO₂, improving overall system efficiency.

Block diagram illustrating the production of synthesis gas (syngas) using electrolysis powered by renewable energy

Design Structure Matrix (DSM) Allocation

In this DSM: 1ELE: Market Strategy (Clean Energy Transition) 2SYN: Product-Level (Syngas Production) 3RCC, 3EEL, 3CRX, 3PCS, 3ESS: Subsystems at Level 3 4DAC, 4ICS, 4CPN, 4SOE, 4PEM, 4EPC, 4NBC, 4AMC, 4HRS, 4SGI, 4EMC, 4INV, 4LIB, 4RFC, 4SSB: Level 4 Components.

Level 1: Market Strategy The market strategy focuses on clean energy transition and sustainable fuels. It sets performance targets like low carbon intensity, cost reduction, energy efficiency, and scalability. This is where the strategy aligns with market needs for clean energy, low-emission transportation fuels, and sustainable plastics production.

Level 2: Syngas Production The product of this strategy is syngas production through renewable energy-powered electrolysis and carbon capture. Syngas serves as an intermediate feedstock for sustainable fuel and plastic production.

Level 3: Key Enabling Component Technologies These are the subsystem-level technologies needed to drive syngas production efficiently and sustainably:

3RCC Renewable Carbon Capture (CO₂ Capture and Transport Technologies): Enables the trapping of CO₂ from industrial emissions or direct air capture, which is essential for syngas production. 3EEL Electrolysis Efficiency (High-Efficiency Electrolyzers): Focuses on electrolysis units that split water with minimal energy loss, leveraging renewable energy like solar and wind to power the system. 3CRX Catalytic Reactors for CO₂-H₂ Reactions: Catalytic systems designed to maximize the efficiency of the reaction between hydrogen and carbon dioxide to form syngas, ensuring high yield and minimal energy consumption. 3PCS Power Conditioning Systems: This system ensures that the renewable energy input is stable, reliable, and properly conditioned to meet the demands of the electrolysis and reactor processes, including day-night cycle energy management. 3ESS Energy Storage Systems: Involves the integration of energy storage solutions (e.g., lithium-ion batteries or regenerative fuel cells) to manage the intermittent nature of renewable energy sources, ensuring a consistent energy supply for the syngas production process.

Object Process Methodology (OPM)

OPM illustrating the production of synthesis gas (syngas) using electrolysis powered by renewable energy

Figure of Merit (FOM)