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Energy
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A R T I C L E I N F O A B S T R A C T
Handling Editor: Henrik Lund Both e-methanol and hybrid methanol production can balance the energy systems storing variable wind and solar
power and reduce emissions by replacing fossil methanol production. It is expected that hybrid methanol pro
Keywords: duction using additional hydrogen from water electrolysis supplemented with purified product gas from biomass
Hybrid methanol gasification will increase methanol yield and result in lower production costs compared to e-methanol, partic
Biomass gasification
ularly when using power sources that are not only available all the time during the year. In this article hybrid
Power-to-MeOH
methanol production with varying hydrogen input from the water electrolysis, e-methanol and biomass
E-Methanol
Biomass-to-methanol gasification-based methanol are evaluated from a techno-economic point of view as a function of key variables.
Synthetic fuels Material and energy balances are estimated using a simulation model in IPSEpro. A key finding is the effect of the
IPSEpro hydrogen input on the efficiency and cost of the hybrid process. Converting CO2 will increase product yield by
101% and only CO by 38.1% compared to biomass-to-methanol production. Additionally, the results show better
economics for hybrid methanol production compared to e-methanol >10–12 €/MWh electricity prices at 100 kt
methanol production scale and <30–35 €/MWh electricity prices better economics than biomass to methanol
with a biomass input of 70 MW.
* Corresponding author.
E-mail address: Kristian.Melin@lut.fi (K. Melin).
https://doi.org/10.1016/j.energy.2023.127202
Received 30 June 2022; Received in revised form 8 March 2023; Accepted 11 March 2023
Available online 10 April 2023
0360-5442/© 2023 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).
E. Anetjärvi et al. Energy 276 (2023) 127202
storage of hydrogen is however also not so attractive due to high cost detail analysis of the techno-economical performance as function of key
and if compression to high pressure or liquefaction of hydrogen is variables with different levels of hydrogen supplementation to the
required it will significantly reduce the efficiency of production due to process and with different annual operation times of the electrolyser, has
high electricity consumption. If biomass is available hybrid methanol not been done to the Author’s knowledge.
using both biomass and electricity is an attractive option. It can both
store intermittent renewable power by using a varying share of biomass 2. Materials and methods
and power as input for methanol production and reduce the need for
biomass input. First, hybrid production processes with and without CO2 utilization
The main focus of this article is studying the hybrid production of e- were reviewed including different possibilities for hydrogen production,
methanol in connection with biomass gasification (see Fig. 1). Hybrid gasification of biomass and synthesising options for methanol produc
methanol production utilizes both water electrolysis and biomass gasi tion with supporting processes.
fication to produce product gas (PG) consisting mostly of hydrogen (H2), Data from the literature review was used as input for the process
carbon monoxide (CO) and carbon dioxide. This product gas is catalyt models in IPSEpro and its advanced powerplant library. Additional
ically synthesized to renewable methanol in a catalytic synthesis reactor component models were built using MDK (Model Development Kit)
[2,3]. [18]. The goal of process modelling was to evaluate the benefits of
In this article different levels of hydrogen, supplementation is stud hybrid methanol production.
ied using both CO and CO2 or only CO for methanol production, and
their benefits are evaluated. Converting both CO and CO2 into methanol
requires more hydrogen but leads to a higher yield of methanol and 2.1. Modelled process cases
allows improved utilization of carbon in biomass to methanol (approx.
90–100%) [2–4]. This reduces the need for feedstock; consequently The methanol production cases studied consist of:
availability of sustainable biomass becomes a less crucial issue. Hybrid methanol production with CO2 utilization (PBtMeOHa) and
without CO2 utilization (PBtMeOHb):
1.2. Previous research • Alkaline electrolyser (AEL) + Fluidized bed gasification and product
gas cleaning + Methanol synthesis loop + Air Supply Unit (ASU) if
Power-to-MeOH concept and gasification of biomass for producing needed.
power- or biomass-to-methanol have been studied individually [2–7,
41]. Both concepts have been found viable for renewable methanol E-methanol (PtMeOH):
production and subsequently, industrial plants are being constructed,
engineered, and planned [1,2]. To gain insights into these processes • AEL + Outside CO2 + Methanol synthesis loop
several modelling studies were conducted with e.g. ASPEN to evaluate
different feasible options or combinations [8–11]. Biomass-to-methanol (BtMeOH):
There have been few detailed reviews on hybrid methanol produc
tion and only a few projects are being planned [2,3]. • Fluidized bed gasification and product gas cleaning + Water Gas
Hybrid production of methanol also in flexible operation has been Shift (WGS) reactor + Methanol synthesis loop + ASU
previously modelled [4,12–16] [42,43], including co-gasification of
biomass and manure [44], for different gasifiers [45] sorption-enhanced All cases involve:
gasification [46]. Furthermore, techno-economical feasibility of
different hybrid methanol concept of the hybrid methanol process • 7,500 annual operating hours
without CO2 capture to Biomass-based and electrochemical methanol • H2 recovery from purge with pressure swing absorption (PSA).
production [17]. In addition, using green hydrogen CO2 from coal to • Waste gas (WG) combustion
methanol production was converted into methanol [47]. Nevertheless, a • District heat (DH) heat limit of 90 ◦ C
2
E. Anetjärvi et al. Energy 276 (2023) 127202
• Process parameters kept constant between cases bed gasifiers because they can accept fuels of varying moisture and
quality. They are already used in the industry for gasification-for
The process models, all modelling principles, assumed operating methanol production. Other types such as entrained flow gasifiers can
values and their references are presented in detail in the supplementary be used for pulverized biofuels. The fuel’s moisture affects the gasifi
material. cation performance, so the biomass is typically dried before gasification.
To produce high heating value PG, biomass is gasified with oxygen and/
2.1.1. Alkaline electrolysis and conditioning or steam [3,27]. In some of the processes also hydrogen is supplemented
Electrolysis is the main hydrogen source for e-methanol and hybrid- from another source than biomass, as in hybrid methanol production
methanol production where (H2O) is split into oxygen (O2) and and the Quebec Enerkem plant hydrogen will be supplied from an 87
hydrogen with electricity according to eq. 1 MW electrolyser [2].
Using only oxygen as a medium can also result in overheating, which
1
H2 O→H2 + O2 (1) damages the gasifier refractory [28]. Therefore, steam is typically added
2
to the oxygen [7]. Oxygen production by membranes or oxygen sepa
Electrolysis with renewable electricity can be used to produce ration from the air can be expensive while hybrid methanol production
renewable hydrogen [3,19]. Water electrolysis accounts currently for benefits from the by-product oxygen from electrolysis [2].
approx. 4% of the world’s total hydrogen production and most of the PG impurities are to be removed to reach a high purity needed for
production is made from fossil fuels such as natural gas (48%), oil catalytic methanol synthesis [2,27] (see Table 1) to prevent catalyst
(30%), and coal (18%) [20]. poisoning in methanol synthesis [6].
Alkaline Electrolysis (AEL), Polymer Electrolyte Membrane (PEM) Post-cleaning can be done in high temperatures and/or low tem
electrolysis and Solid oxide electrolyser cells (SOECS) electrolysis have perature (below 250 ◦ C) applications. In the low-temperature water
been the key technologies suggested for hydrogen production [5, and/or solvents are used to clean the PG. In AGR (Acid Gas Removal), for
19–25]. Among these three, Alkaline and PEM electrolyser technologies H2S only or together with CO2, solvents like MEA (Monoethanolamide),
are in the commercial stage and SOECS is still in development [22]. Of Selexol or Rectisol can be used to achieve high standards for the removal
the viable technologies, AEL was selected for this study. When waste [3,4,7]. Hot gas cleaning (above 400 ◦ C) uses catalysts and
hydrogen is available, using it is a viable option and in the future, SOEC high-temperature ceramic filters to clean the PG [3,27].
can become a favourable option [22,26]. The gasification system in the BtMeOH and PBtMeOH cases consists
The AEL produces all the hydrogen in the P2MeOH case and a sig of a biomass dryer before product gas cleaning. The biomass is assumed
nificant part of it in the hybrid cases. The oxygen produced as a by- to be woody biomass [29] and its properties are presented in the sup
product by the AEL was utilised in gasification and reforming while plementary material.
the excess portion was sold. A separate model for the AEL process was The biomass dryer uses steam as the heat medium. The steam goes to
utilised in this study. the dryer at 94 ◦ C and leaves at 70 ◦ C. The biomass is dried from 20% to
The alkaline electrolyser works at an operating temperature of 90 ◦ C 5% moisture. The dried fuel leaves the dryer at a temperature of 60 ◦ C.
and a pressure of 4 bars. Water is fed to the electrolyser at 25 ◦ C. The The specific heat and electricity usage is set to 1300 kWh/tevap and 32
cooling water leaves the electrolyser at a temperature of 75 ◦ C and is kWh/tdry, fuel [4,14]
further heated with process heat to be utilised in DH. With these oper After drying, fluidized bed gasification is done with a 1:1 ratio of
ating parameters, the electrolyser efficiency is 70.7% based on the lower oxygen and steam (at 215 ◦ C) at a pressure of 4 bars [4,14].
heating value (LHV) of hydrogen. The gasifier has a 98% conversion efficiency from biomass to gas and
Depending on the gasification technique or medium used, the H2, CO a heat loss of 0.8% [4]. Gasifiers produce PG that is not in equilibrium;
(and CO2) ratio can be suboptimal and more hydrogen is required. however, after catalytic reforming and filtration, the gas composition
Therefore, adjustment of the gas H2/CO ratio i.e. PG conditioning is can be assumed to be in equilibrium and the gasification model assumes
needed. There are two main possibilities for this: The traditional way of PG to be in equilibrium (see Table 2) representing the fluidized bed
conditioning is to use a WGS reactor, where a portion of CO is turned gasifier, filter, and the catalytic reformer. The gasifier model outlet
into H2 and CO2 with steam and in presence of a catalyst (see eq. (4)) for temperature is set to 950 ◦ C and the pressure drop to 0.6 bars [4].
optimal H2/CO ratio. In a hybrid plant, the amount of H2 required for In the PBtMeOHa case, the oxygen produced from electrolysis is fed
utilizing only CO or both CO and CO2 is added to the PG. The PG is to the gasifier. Whereas in the BtMeOH case, all the oxygen is provided
heated, cooled and pressurized. Tars and methane are reformed, which by ASU and its electricity consumption is 0.37 kWh/kg,O2 [30].
offers the benefit of cleaning the PG as well [2,3,7]. Consequently, in the PBtMeOHb case, additional oxygen is needed,
In the BtMeOH case, no additional hydrogen is provided, so the which is provided by ASU.
hydrogen stoichiometry in the PG is adjusted with a WGS reactor. In this The PG cleaning in these cases is done in two stages. In the first stage,
case, the WGS reactor is situated after reforming and PG cooling. Before waters scrubbing is employed for the removal of the impurities such as
the reactor, steam is injected into the stream to achieve a steam-to-CO ammonia and in the second stage, AGR is used for H2S and/or CO2
ratio of 1.8 at the inlet. The reactor inlet temperature is 200 ◦ C. removal.
Furthermore, the reactor outlet temperature is adjusted to 405 ◦ C [4]. The PG coming from reforming in hybrid and BtMeOH cases is cooled
3
E. Anetjärvi et al. Energy 276 (2023) 127202
Table 2 It compares the CO and CO2 molar amounts, COR = 1, for 100% CO2
Gasifier model outlet PG composition. and COR = 0 for 100% CO. Heat release from the exothermic synthesis
Component Amount [vol%] reaction, methanol per pass yield and production of unwanted side-
products, excluding water is higher for low COR. On the opposite
CO 36.4
CO2 20.9 higher COR increases water production, and H2 consumption and de
H2 42.5 creases methanol yield per pass, increasing the need for gas recircula
CH4 1.2E-02 tion. Typically, there is a distillation unit after the reactor separates
N2 0.1 water and other dissolved impurities from methanol [4,6,31,32].
H2S 4.1E-02
Total 100
Methanol synthesis reactors typically operate in the range of approx.
200–300 ◦ C and in the pressure range of approx. 50–100 bar in
low-temperature operations [4,6,27].
to 200 ◦ C before two-stage water scrubbing. In the water scrubber, the In all the cases, after cleaning and conditioning, the cleaned PG (H2
liquid outlet temperatures are the following: 60 ◦ C in the 1st stage and and CO2 in PtMeOH case) is heated, pressurized, and fed to a single
30 ◦ C in the 2nd stage. The PG leaves the water scrubber at 45 ◦ C [4], isothermal methanol synthesis reactor at 50 bar and isothermal tem
followed by pressurisation to 21 bar and aftercooling to 60 ◦ C. In the perature of 230 ◦ C. A stoichiometric ratio of 2 is used [32]. Heat is
PBtMeOHa case only H2S is removed, but in the BtMeOH and PBtMeOHb liberated in the reactions and the reactor outlet is recovered at 215 ◦ C.
cases both H2S (<1 ppm %) and CO2 (≤2.0 mol%) are removed. Rectisol Subsequently, the methanol reactor outlet gas is fed and cooled to 60 ◦ C
(cold methanol) is employed as an absorption medium and the specific and the condensed methanol and water are separated from the gas.
electricity use is 7600 kJ/kmolremoved, including the electricity needed Next, the liquid product is fed to distillation separating methanol
for low-temperature cooling [4]. from water, operated at 3.5 bars [14]. The heat used for the distillation
of methanol is obtained both from methanol synthesis, condensing of
2.1.3. Methanol synthesis loop products and waste gas combustion. Both the methanol distillate and the
Methanol can be synthesized from the PG consisting of H2 and CO2 water bottom product are cooled.
and/or CO. In synthesis three main reversible chemical reactions take In all the cases except PtMeOH, 95% [4] of the unreacted gasses from
place: the gas-liquid separator are recirculated back to the reactor. Whereas in
/ the PtMeOH case, more gases are combusted, due to the need to pre-heat
CO2 + 3H2 ⇌CH3 OH + H2 O, ΔHr,298 K,1 atm = − 49, 4 kJ mol (2)
the methanol reactor feed. The main part of unreacted gases are pres
/ surized and recycled to the reactor feed but a small part (purge stream) is
CO + 2H2 ⇌CH3 OH, ΔHr,298 K,1 atm = − 90, 5 kJ mol (3)
fed to the PSA unit to recycle 90% of the hydrogen back. The PSA has a
/ specific electric power consumption of 20 kWh/kgH2,recovered [10,33].
CO + H2 O⇌CO2 + H2 , ΔHr,298 K,1 atm = − 41, 1 kJ mol (4)
The non-recycled stream from PSA is sent to WG combustion, using
Reaction eq. (2) CO2 hydrogenation, Reaction eq. (3) CO hydroge oxygen or air. The heat from combustion is recovered and utilised inside
nation and eq. (4) Water Gas Shift (WGS) reaction. These reactions are the process.
exothermic in nature. reactions eqs. (2) and (3) favour high pressures In general heat integration and the utilization of waste heat, are
and low temperatures. Catalysts are used to enhance reaction kinetics needed for high total process efficiency [7,14]. In this study excess heat
[5,6,10]. with a temperature above 90 ◦ C is utilised for DH. Auxiliary equipment
Production of methanol from CO has been observed to happen in cases consists of compressors, heat exchangers, mixers, and steam
mainly through WGS-reaction and hydrogenation of CO2. In commercial injectors. They and heat integration are described more in supplemen
reactors, CO is generally utilised to produce methanol from fossil and tary material.
renewable feedstock sources and a major part of CO2 is removed and
only approx. 4%-vol CO2 remains is the fed to methanol synthesis [2,4]. 2.1.4. Process performance and economic parameters
Recently it has also become possible to synthesize methanol from Process performance parameters are calculated for the evaluation of
CO2 directly, used in the P-to-MeOH processes [2,4]. Nowadays both CO the cases. Methanol production efficiency ηMeOH is determined as eq. (7):
and CO2 methanol synthesis are effective processes and have been qm,MeOH LHVMeOH
commercially proven [2]. ηMeOH = (7)
qm,biomass,wet LHVbiomass,wet + Pe,tot
PG produced from biomass gasification contains both CO and CO2.
Catalysts and reactors have been developed for combined CO2 and CO where qm,MeOH and qm,biomass,wet are produced methanol and used wet
conversion, which have also high conversion rates of methanol [2]. E.g., biomass mass flows, respectively, LHVMeOH and LHVbiomass,wet are the
the developed liquid-phase slurry reactors, that are not affected by a methanol and wet biomass LHV, respectively, and Pe,tot is the total
mixture of CO and CO2 [7]. Separate synthesis of CO and CO2 in hybrid electricity power usage of the process. DH production efficiency ηDH is
plants is also possible if CO and CO2 separation from each other is a determined as eq. (8):
feasible option [2,3,32].
In the stream containing both CO and CO2, the mole relation between ηDH =
Q>90 C Heat
(8)
H2, CO and CO2 is given by the following eq. (5): qm,biomass,wet LHVbiomass,wet + Pe,tot
nH2 − nCO2
SN = (5) Where Q>90 C Heat is DH potential heat. The total efficiency of heat and
nCO + nCO2 methanol production ηtot can be determined as eq. (9):
Where SN is the stochiometric number needed for the reaction, nH2 , nCO ηtot = ηMeOH + ηDH (9)
subscription the H2, CO and CO2 mole amounts, respectively. This comes
The carbon utilization to methanol ηcarbon , is determined as eq. (10):
from hydrogen needed in reactions to methanol. The optimum value for
the SN is 2. Another parameter different in each case concerning the ncarbon,MeOH
ηcarbon = (10)
methanol reactor feed is the COR influencing the performance of ncarbon,biomass
methanol synthesis as eq. (6):
Where ncarbon,MeOH is the carbon mole amount out in methanol and
nCO2
COR = (6) ncarbon,biomass subscriptionssubscriptions the carbon mole amount in the biomass
nCO + nCO2
4
E. Anetjärvi et al. Energy 276 (2023) 127202
Table 3
Values of initial inputs and outputs.
Inputs/Outputs Value Reference
5
E. Anetjärvi et al. Energy 276 (2023) 127202
Fig. 7. Initial cost, revenue and LCOP estimation in 100 kt, error estimate in
capital charge cost ±30%.
Fig. 10. Sensitivity of LCOP on CO2 price in 100 kt MeOH production cases.
electricity, biomass and CO2 price and production scale are illustrated in
Figs. 8–11.
Second, BtMeOH and hybrid cases were scaled to 70 MW biomass
input and the results are presented in Fig. 12, Figs. 13 and 14. In Fig. 16
LCOP as function of change in Total capital investment compared to the
base case is illustrated and in Fig. 17 the effect on LCOP of annual
operation hrs of the electrolysers is illustrated. In addition, more
detailed results are presented in the supplementary material.
The methanol production efficiency (see eq. (7)) of the hybrid cases
compared to the other cases appears promising; The best efficiency is
achieved for the PBtMeOHb case (61.7%), 2nd best the for BtMeOH case
(60.7%), whereas the PBtMeOHa case is 3rd and the last is PtMeOH case Fig. 11. Sensitivity of LCOP on production scale in 100 kt. MeOH produc
(52.6%). The differences are explained by the differences in the COR and tion cases.
methanol per pass conversion. The per-pass conversion efficiency of CO-
Fig. 12. Energy usage and production in 70 MW of biomass usage cases (error
Fig. 8. Sensitivity of LCOP on electricity price in 100 kt MeOH produc
estimate ±5%).
tion cases.
6
E. Anetjärvi et al. Energy 276 (2023) 127202
followed by the 2nd PBtMeOHb case (85.0%) and 3rd case PtMeOH case
(84.9%). Consequently, the BtMeOH case is last (79.7%). For the hybrid
cases, the low-temperature heat from the electrolyser was not utilised in
biomass drying which would increase the total efficiency for the hybrid
cases.
The PBtMeOHa case performs well in the utilization of carbon to
methanol (89.8%) followed by the 2nd case PtMeOH case (80.9%).
Whereas the PBtMeOHb case is 3rd (61.5%) and the BtMeOH case is the
last (44.6%).
The PBtMeOHa has the highest carbon utilization because enough
hydrogen is produced to convert not only CO but also CO2 into methanol
The PtMeOH case has lower carbon utilization due to the combustion of
more product gas to pre-heat the methanol reactor feed.
The PBtMeOHb and BtMeOH case has the lowest carbon utilization
Fig. 13. Total Capital Investments in 70 MW of biomass usage cases (error due to not utilizing the CO2 produced from the gasification but removing
estimate±30%).
it from the process in AGR. PBtMeOHb has higher carbon utilization
than the BtMeOH case because no CO is converted into CO2, which is
removed from the process. Additionally with a lower purged and com
busted gas amount, e.g. employing electrical heating even higher carbon
efficiencies could be reached for all cases.
The carbon utilization leads to different biogenic CO2 emissions for
the cases presented in the supplementary material. Even for biogenic
emissions, fewer emissions are a benefit concerning climate change,
particularly for short-term time perspective for GHG emission re
ductions. In 100 ktons of MeOH production cases, the biogenic CO2
emissions are PBtMeOHa (approx. 12 ktons/y), PBtMeOHb (approx 59
ktons/y), PtMeOH (approx 32 ktons/y.) and BtMeOH (approx. 164
ktons/y). However, it should be noted that PtMeOH can use more CO2
from an existing plant as a raw material than what is emitted so it will
result in a reduction in CO2 emissions.
Fig. 14. Initial Cost, Revenue and LCOP estimation of biomass usage cases
Of the hybrid cases for the PBtMeOHa case the methanol yield per
error estimate ±30% of capital charge).
biomass increases most approx. 101% compared to the BtMeOH case.
With PBtMeOHb the yield increased only by 38.1% compared to the
rich gas is higher than for CO2. Also, in the PtMeOH case, more product BtMeOH case. The yield increase from PBtMEOHb to PBTMeOHa is
gas is combusted to pre-heat the methanol reactor feed lowering the approx. 46%.
methanol production efficiency.
It is estimated that the used simulation model could predict the
3.2. Economical evaluation of 100-kiloton cases
carbon efficiency for the process with (±5%) accuracies due to inac
curacies in the prediction of gasification and the methanol production
The estimated TCI of 100 ktons of MeOH production is 2nd highest
efficiencies differences between the cases except for the PtMEOH case
for the PBtMeOHb (180 M€), 3rd for the PBtMeOHa case (197 M€),
are rather insignificant. The electrolysis efficiency has an effect on the
lowest for the BtMeOH case (164 M€) and highest for the PtMeOH case
relative conversion efficiency of biomass vs. CO2 into methanol.
(235 M€). The estimates are mostly based on a study made by Hannula I.
On the other hand, when comparing marginal efficiencies (see
[4], which estimates the accuracy to be − 15%/+30%. For new tech
Table 13 in support material) for the 70 MW biomass input the effi
nology typically learning takes place, decreasing the investment costs
ciencies differ more between the hybrid cases. In the case PBtMeOHb
when several plants are built. In addition, estimating the investment cost
case 27.9 MW more electricity is utilised in the process and 18.1 MW
accurately for novel technology is difficult and therefore in this study, an
more methanol is produced compared to the BtMEOh case. Approxi
accuracy of ±30% is assumed.
mately 0.65 MW of methanol/MW electricity is produced. The reason for
The reason why PtMeOH case and hybrid cases TCI is higher, comes
high efficiency compared to the BtMeOH case is that the produced
from the high installed equipment cost of the electrolyser, estimated by
hydrogen replaces more inefficient hydrogen produced in the BtMeOH
Hannula [4] to be approx. 1000 €/kWe with no scaling with power, as
case from CO by WGS. When increasing the hydrogen input from case
large electrolysers (>20 MW scale) don’t yet exist yet 2020 [22]. As the
PBtMEOHb further to PBtMeOHa 54.1 MW of additional electricity is
hybrid cases are a hybrid of PtMeOH and BtMeOH cases they fall be
used and methanol output increases by 29.9 MW. Approximately only
tween these two in the TCI estimations due to the smaller capacity of the
0.55 MW methanol/MW electric power is obtained. The marginal effi
installed electrolyser. The investment costs of electrolysers are esti
ciency is lower in this case because no WGS is needed for hydrogen
mated to decrease in the future, as electrolysers are scaled up [2,22,35]
production, however, the efficiency is still higher than the methanol
and electrolyser projects are supported by European Union (EU) [36,
production efficiency for the PtMeOH case because less gas is combusted
37]. Cost reductions will make the PtMeOH and hybrid processes
to pre-heat the methanol reactor feed.
competitive with gasification-only processes in an economic sense and
The PBtMeOHa case is 2nd with a DH production efficiency of 26.3%
the development of high-efficiency SOEC electrolysis on an industrial
and the best efficiency is achieved by the PtMeOH case (32.3%). The 3rd
scale can further improve the yield of the hybrid processes. The Hybrid
and 4th are PBtMeOHb (23.3%) and BtMeOH cases (19.0%).
process does not need so high-capacity electrolysers enabling the use of
The differences in the DH production efficiencies come from the heat
electrolysers sooner.
integrations and for the best PtMeOH case, all its excess heat can be
The hybrid cases also fall in the middle in the initial LCOP of
utilised in DH. Other cases produce lower-temperature waste heat in the
methanol evaluations. The LCOP of methanol for the PBtMeOHa case is
water scrubber and utilize some of its high-temperature heat.
511 €/ton (26 €/GJ) and the for PBtMeOHb case 448 €/ton (22 €/GJ).
The PBtMeOHa case is 1st in terms of overall efficiency (85.8%)
The lowest LCOP of 370 €/ton (18 €/GJ) is achieved with the BtMeOH
7
E. Anetjärvi et al. Energy 276 (2023) 127202
case and the highest is with the PtMeOH case with 728 €/ton (36 €/GJ). including gasification can be operated flexibly, by varying input of
However, it should be noted that the BtMeOH case does not help in hydrogen to the process depending on the electricity price and avail
balancing the energy system, unlike the hybrid and PtMeOH cases. ability. For different hydrogen inputs, there would be several possible
In addition in many cases, only a limited amount of biomass is operating modes beyond using only CO or both CO and CO2 for meth
available without additional infrastructure for transport and collection anol production. From Figs. 4 and 12, it can be seen how varying CO2
for example as by-products from an industrial sawmill, pulp production utilization affects the hybrid plant electricity input and methanol output
plant etc. It means that in hybrid cases it is possible to increase the for the 70 MW biomass usage and 100 kt MeOH production cases.70 MW
production capacity, which is an advantage. biomass requires 89.7 MW of electricity producing 95.0 MW of MeOH in
BtMeOH case has a low initial LCOP due to smaller investment and the case PBtMeOHa and 35.6 MW of electricity and producing 65.1 MW
utilization of biomass. In hybrid and PtMeOH cases the high use and of MeOH the in the case PBtMeOHb.
high yearly cost associated with electricity use and the higher annual The operating mode also affects the LCOP of methanol (Figs. 7 and
capital charge cost due to electrolysis investment is the reason for higher 13). The LCOP for both PBtMeOHa at 461€/ton with a TCI of 242 M€ and
initial LCOP. PBtMeOHb at 462 €/ton with a TCI of 164 M€ are very close to each
In the future, there can be a large amount of low-cost variable other. The bigger MeOH production capacities make up for the bigger
renewable electricity available, when a lot of investments in wind and TCI. The sensitivity analysis reveals that below 50 €/MW electricity
solar power have been done [36]. The effect of electricity price on the prices, it is beneficial to utilize CO2 and at high electricity prices the
LCOP of methanol is illustrated in Fig. 8. The PBtMeOHa case LCOP opposite. But depending on the production scale and whether payback of
follows very closely to the PBtMeOHb case. At low electricity prices the bigger electrolyser or only operating costs are considered the con
(<21 €/MWh) it is more economical to utilize the CO2 in the hybrid ditions when to utilize CO2 and CO or only CO vary (Figs. 8 and 15).
process than remove it. The electricity price has a sharp effect on the The future energy system is expected to have a high share of solar
LCOP of the PtMeOH case compared to the BtMeOH case. The effect of and wind power with varying production and price [36]. Switching
electricity price on hybrid cases is in the middle of these two. When the between different modes in the hybrid process could help to balance the
electricity price gets low enough the PtMeOH (<15 €/MWh) and hybrid production and demand of electricity and store electricity in the form of
cases (<18 €/MWh) LCOP becomes even lower than the BtMeOH case. It methanol as well. Additional investment to the WGS reactor approx. 2
should also be noted that these results include the capital charge cost of M€) could bring more flexibility enabling the hybrid process to operate
the electrolyser so in the case an electrolyser already exits it becomes as the BtMeOH process. The electricity needed is low (7.7 MW). but also
profitable to run the process in hybrid mode even with a higher elec the MeOH production is lower (47.2 MW). For 70 MW biomass, the
tricity price. estimated LCOP of the BtMeOH case is 415 €/ton and the TCI 124 M€.
Biomass costs typically vary from under approx. 16 €/MWh to over All the previous results apply for high 7500 h of annual operation of the
26 €/MWh depending on the biomass and the locations of the plant [38]. electrolyser, but when the annual operation time of the electrolyser is
The impact of biomass cost on profitability is illustrated in Fig. 9. reduced as illustrated in Fig. 17 the LCOP cost steeply increases for case
Logically, the hybrid cases are not as highly affected by the change in PtMEOH The hybrid cases res in only small changes in the LCOP when
biomass price as the BtMeOH case but still benefits from lower biomass the electrolyser operation time is reduced. The reason is that in the
price. PtMeOH, case reducing the electrolyser annual operation time requires
The uncertainty of the price of CO2 and the capture method increases that hydrogen and CO2 have to be stored or the whole process has to be
the uncertainty towards the PtMeOH case competitiveness versus the overdesigned to reach the same annual production capacity of methanol
other cases and its impact on profitability is illustrated in Fig. 10. The In the hybrid cases including the WGS reactor, the process still can be
CO2 price is estimated to vary between e.g., 45–135 €/ton in Direct Air operated as BtMEOH case when the electrolyser is not in use.
Capture (DAC) [2]. This is illustrated in the Figure. On a large scale,
low-cost high concentration sources of CO2 are scarce such as fermen
tation gas from bioethanol production and generally, CO2 has to be 3.4. Comparisons to previous studies
separated from flue gas involving high costs.
The production scale affects the LCOP of the cases as well. This effect Literature data of techno-economic performance are summarised in ,
was estimated with an assumed capacity exponent of 0.6 [24] for the Tables 4 and 5 and compared to the results of this study and all effi
changed plant investment and O&M costs. From Fig. 11, can be seen that ciencies compare well with previous studies, but lower efficiency is
the LCOP of the cases decreases with the increased capacity. On the obtained of total efficiency in the PBtMEOH case compared to Ref. [14].
other hand, too large a production scale can be unfeasible due to the In addition, the BtMeOH and PtMeOH correspond well with literature
excess need for capital investment, biomass, and/or electricity. values.
Subsequently, in Fig. 16 the influence of Fixed Capital Investment The LCOP of PBtMeOHa in this study s approx. 10 €/GJ higher (see
(FCI) on the LCOP for the different cases is illustrated as a function of Table 3) compared to Clausen et al. [14] and approx. 100 €/ton higher
change in FCI compared to the based case and FCI generally has a bigger for three cases compared to Ref. [6], but in this study, it is unclear if CO2
impact on the LCOP than other items such as maintenance and personnel is utilised or only CO. The differences are explained by different
costs.
Furthermore, the hybrid cases, especially PBtMeOHa, have an
advantage from a biomass and logistics point of view due to the higher
yield of product per ton of biomass it is possible to reach a bigger
methanol production scale with lower biomass amount (see Fig. 5). The
large volume of biomass and its transportation distance, as well as the
small scale of biomass gasification plants compared for example to
natural gas-based methanol production plants, are significant challenges
with biomass-to-methanol processes [2].
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E. Anetjärvi et al. Energy 276 (2023) 127202
Table 4
Hybrid cases compared to previous studies. PBtMeOHb in brackets.
MeOH Efficiencies LCOP Investment Notes/ Ref.
production differences
scale
9
E. Anetjärvi et al. Energy 276 (2023) 127202
10
E. Anetjärvi et al. Energy 276 (2023) 127202
PBtMeOH the product yield increased by 101% compared to manuscript, developed the methodology, and calculated and organized
BtMEOH and carbon yield increased to 89.8% and a similar LCOP of the presented data. KM and EV wrote and revised the manuscript and
461 €/ton as in the previous case is obtained. The advantage is that: supervised the work.
enough oxygen for the gasification is produced and no separation of
CO2 is needed. the disadvantage is that: a more expensive electro Declaration of competing interest
lyser with a higher capacity is needed.
• The hybrid cases can store wind and solar power by varying The authors declare that they have no known competing financial
hydrogen input to the process from the electrolysers and therefore interests or personal relationships that could have appeared to influence
LCOP remains at lower levels even with a low annual operation level the work reported in this paper.
compared to e-methanol production.
• Both hybrid cases reduce the biogenic CO2 emissions compared to Data availability
biomass-based methanol production.
Data will be made available on request.
Authorship statement
Fig. 18. Hybrid methanol with CO2 utilization (PBtMeOHa) process model case with 100 kt of MeOH production in IPSEpro.
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E. Anetjärvi et al. Energy 276 (2023) 127202
Fig. 19. Hybrid methanol without CO2 utilization (PBtMeOHb) process model case with 100 kt of MeOH production in IPSEpro.
Fig. 20. E-methanol (PtMeOH) model case with 100 kt of MeOH production in IPSEpro.
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E. Anetjärvi et al. Energy 276 (2023) 127202
Fig. 21. Bio-methanol (BtMeOH) process model case with 100 kt of MeOH production in IPSEpro.
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E. Anetjärvi et al. Energy 276 (2023) 127202
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