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Advances in Science, Technology & Innovation
IEREK Interdisciplinary Series for Sustainable Development

Inamuddin · Rajender Boddula ·


Mohd Imran Ahamed · Anish Khan Editors

Carbon Dioxide
Utilization
to Sustainable Energy
and Fuels
Advances in Science, Technology & Innovation
IEREK Interdisciplinary Series for Sustainable
Development

Editorial Board
Anna Laura Pisello, Department of Engineering, University of Perugia, Italy
Dean Hawkes, University of Cambridge, Cambridge, UK
Hocine Bougdah, University for the Creative Arts, Farnham, UK
Federica Rosso, Sapienza University of Rome, Rome, Italy
Hassan Abdalla, University of East London, London, UK
Sofia-Natalia Boemi, Aristotle University of Thessaloniki, Greece
Nabil Mohareb, Faculty of Architecture - Design and Built Environment,
Beirut Arab University, Beirut, Lebanon
Saleh Mesbah Elkaffas, Arab Academy for Science, Technology, Egypt
Emmanuel Bozonnet, University of la Rochelle, La Rochelle, France
Gloria Pignatta, University of Perugia, Italy
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Luciano De Bonis, University of Molise, Italy
Stella Kostopoulou, Regional and Tourism Development, University of Thessaloniki,
Thessaloniki, Greece
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Inamuddin  Rajender Boddula 
Mohd Imran Ahamed  Anish Khan
Editors

Carbon Dioxide Utilization


to Sustainable Energy
and Fuels

123
Editors
Inamuddin Rajender Boddula
Department of Applied Chemistry CAS Key Laboratory of Nanosystems
Faculty of Engineering and Technology and Hierarchical Fabrication
Zakir Husain College of Engineering Beijing, China
and Technology
Aligarh Muslim University Anish Khan
Aligarh, India Department of Chemistry
Faculty of Science
Mohd Imran Ahamed King Abdulaziz University
Department of Chemistry Jeddah, Saudi Arabia
Faculty of Science
Aligarh Muslim University
Aligarh, India

ISSN 2522-8714 ISSN 2522-8722 (electronic)


Advances in Science, Technology & Innovation
IEREK Interdisciplinary Series for Sustainable Development
ISBN 978-3-030-72876-2 ISBN 978-3-030-72877-9 (eBook)
https://doi.org/10.1007/978-3-030-72877-9

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Contents

Chemical Valorization of CO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


Esperanza Ruiz Martínez and José María Sánchez Hervás
Progress in Catalysts for CO2 Reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Maria do Carmo Rangel
Fuel Generation from CO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Mariany C. Deprá, Ihana A. Severo, Rafaela B. Sartori, Patrícia Arrojo,
Leila Q. Zepka, and Eduardo Jacob-Lopes
Thermodynamics of CO2 Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Joshua Gorimbo and Ralph Muvhiiwa
Enzymatic CO2 Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Pravin D. Patil, Anup D. Chahande, Deepali T. Marghade, Vivek P. Bhange,
and Manishkumar S. Tiwari
Electrochemical CO2 Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
I. A. Novoselova, S. V. Kuleshov, and A. A. Omel’chuk
Supercritical Carbon Dioxide Mediated Organic Transformations . . . . . . . . . . . . 137
Bubun Banerjee and Gurpreet Kaur
Theoretical Approaches to CO2 Transformations . . . . . . . . . . . . . . . . . . . . . . . . . 153
Hossein Sabet-Sarvestani, Mohammad Izadyar, Hossein Eshghi,
and Nazanin Noroozi-Shad
Carbon Dioxide Conversion Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Sidra Saqib, Ahmad Mukhtar, Sami Ullah, Muhammad Sagir, M. Bilal Tahir,
Rabia Amen, Muhammad Babar, Abdullah G. Al-Sehemi, Muhammad Ali Assiri,
and Muhammad Ibrahim
Closing the Carbon Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Anoop Singh, Prerna Mahajan, and Sandeep Arya
Carbon Dioxide Utilization to Energy and Fuel: Hydrothermal
CO2 Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Demet Ozer
Ethylenediamine–Carbonic Anhydrase Complex for CO2 Sequestration . . . . . . . . 253
Egwim Evans Chidi, G. K. Ezikanyi, Onyeaku Ugoona Sandra,
and Joseph Peter Shaba
Green Pathway of CO2 Capture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Amita Chaudhary
Carbon Derivatives from CO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Abbas Ghareghashi and Ali Mohebbi

v
vi Contents

Catalysis for CO2 Conversion; Perovskite Based Catalysts . . . . . . . . . . . . . . . . . . 297


Osarieme Uyi Osazuwa and Sumaiya Zainal Abidin
Carbon Dioxide Conversion to Useful Chemicals and its Thermodynamics . . . . . . 311
Pallavi Jain and A. Geetha Bhavani
Carbon Dioxide-Based Green Solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Saraswati Soren, Tejaswini Sahoo, Jagannath Panda, Deepak Kumar Senapati,
J. R. Sahu, C. K. Rath, and Rojalin Sahu
State-Of-The-Art Overview of CO2 Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Grazia Leonzio
Chemical Valorization of CO2

Esperanza Ruiz Martínez and José María Sánchez Hervás

Abstract Keywords

     
The growing CO2 atmospheric concentrations, linked CO2 recycling Renewable energy storage CO2 to
with detrimental global warming, and the declining fossil chemicals CO2 to fuels CO2 to polymers CO2 to

 
resources derived from power generation, transportation building materials Climate change Greenhouse gas
and industries are of great environmental and sustainabil- mitigation Chemical processes CO2 utilization
ity concerns. Chemical valorization of CO2 into fuels,
chemicals, polymers and construction materials is a Abbreviations
promising tool to reduce fossil fuel depletion and
greenhouse gas emissions, contribute to decarbonization AT Austria
of energy, transport and industrial sectors and to fulfill BE Belgium
climate goals, while storing renewable energy and Bio Biological
generating revenue. Chemical valorization of CO2 has BP British Petroleum
the potential to generate products with similar or CA Canada
improved quality and with smaller carbon and water Cat Catalytic
footprints, energy consumption and production costs than CH Switzerland
traditionally produced counterparts. However, the deploy- CN China
ment of these CO2-based products is limited to about 10 coSOEC Co-electrolysis of water and CO2 in Solid
million tons of CO2 per year, due to the early stage of Oxide Electrolyte Cells
development of some valorization routes, the need for CRT Chemical Reaction Engineering
low-carbon, cheap and renewable energy and hydrogen d Day
and the fulfillment of quality standards and regulations. DE Germany
This chapter focuses on valorization technologies DEA Danish Energy Agency
approaching commercialization, consuming huge DGC Danish Gas Technology Centre
amounts of CO2 and integrating renewable energy, and DK Denmark
reviews the maturity, the scaling-up potential, the DME Dimethyl ether
climatic, economic and environmental benefits and the DNV Det Norske Veritas
bottlenecks for commercialization of the technologies and DTU Technical University of Denmark
the market size and price of the synthesized products. ECN Energy research Centre of the Netherlands
ES Spain
EU European Union
FI Finland
FR France
FT Fischer–Tropsch
E. Ruiz Martínez (&)  J. M. Sánchez Hervás HU Hungary
Unit for Sustainable Thermochemical Valorisation, CIEMAT, IN India
Avenida Complutense, 40, 28040 Madrid, Spain IS Iceland
e-mail: esperanza.ruiz@ciemat.es IEA International Energy Agency
J. M. Sánchez Hervás IET Institut fur Energietechnik
e-mail: josemaria.sanchez@ciemat.es

© The Author(s), under exclusive license to Springer Nature Switzerland AG 2022 1


Inamuddin et al. (eds.), Carbon Dioxide Utilization to Sustainable Energy and Fuels,
Advances in Science, Technology & Innovation, https://doi.org/10.1007/978-3-030-72877-9_1
2 E. Ruiz Martínez and J. M. Sánchez Hervás

IT Italy dioxide capture or allows obtaining an economic revenue


JP Japan (Centi 2009; Zhu 2019).
KEI Knowledge Energy Institute There are different potential technological routes, based
kЄ Thousands of Euros mainly on catalytic, biochemical, electrochemical and min-
MCi Mineral Carbonation International eralization processes, for chemical conversion of carbon
MSW Municipal Solid Waste dioxide into a variety of added value products, such as
Mt Millions of tons methane, methanol, dimethyl ether (DME), gasoline, diesel,
nda No data available jet fuel, ethanol, formic acid, polymers and building mate-
NO Norway rials (Zhu 2019; Chauvy et al. 2019).
NL Netherlands Chemical valorization of wasted carbon dioxide in the
NL-DE Dutch-German collaboration form of materials, chemicals and fuels may result in a series
NZ New Zealand of environmental benefits, as long as renewable power
P2G Power-to-Gas sources are utilized for the conversion of carbon dioxide. In
PFI Prüf- und Forschungsinstitut this manner, CO2 can become from a detrimental greenhouse
PL Poland gas producing global warming, into a worthwhile, renew-
QAFAC Qatar Fuel Additives Company Limited able, endless and carbon neutral source of chemicals,
RFA Renewable Fuel Association materials and combustibles for the future (Ganesh 2014;
RWGS Reverse Water Gas Shift Goeppert et al. 2014; Centi 2009).
SE Sweden The climate benefits linked with carbon dioxide utiliza-
SLF Swiss Liquid Future tion mainly come from substituting a fossil-based product,
t Ton such as conventional chemicals, fuels or polymers, by the
Tec Technology corresponding alternative product derived from carbon
TRL Technology Readiness Level dioxide and having longer life cycle of carbon dioxide
TW Taiwan emissions. Key aspects to be consider in evaluating the cli-
US United States of America mate benefits of carbon dioxide valorization include: the
WBT White Biotech origin of carbon dioxide, derived from fossil fuels or bio-
y Year mass or captured from air, the conventional product being
ZA South Africa replaced by the carbon dioxide based product, the amount
ZSW Zentrum für Sonnenenergie- und and type of energy required for carbon dioxide conversion,
Wasserstoff-Forschung Baden-Württemberg the retention time of carbon dioxide in the product and the
scale of the potential of carbon dioxide utilization (Interna-
tional Energy Agency (IEA) 2019).
Carbon dioxide obtained from biomass or directly from
the air can provide neutral or even negative carbon emissions
1 Introduction
for carbon dioxide valorization routes that involve the
long-term permanent storage of carbon in the final product,
Carbon dioxide is a waste gas resulting mainly from fossil
such as in construction materials (International Energy
fuel combustion for transportation and power generation and
Agency (IEA) 2019).
from other industrial processes. Carbon dioxide has a high
The carbon retention time for carbon dioxide valorization
greenhouse gas potential and is regarded as one of the
applications ranges from barely one year for fuels, until a ten
foremost contributors to climate change and global warming
of years for the majority of chemicals, to centuries and
(Ganesh 2014; Goeppert et al. 2014).
millions of years for polymers and construction materials,
The production of energy, fuels, chemicals and materials
respectively (International Energy Agency (IEA) 2019).
from fossil sources continues to play a crucial role (Goeppert
The potential contribution of carbon dioxide utilization to
et al. 2014). On account of continuous increase in the
the fulfillment of climate objectives will be determined by
atmospheric concentration of carbon dioxide and progressive
the timeframe and speediness of the scaling-up of these
depletion of fossil fuel reserves resulting from extensive
chemical valorization pathways (Chauvy et al. 2019; Inter-
power generation, chemical valorization of emitted carbon
national Energy Agency (IEA) 2019).
dioxide to fuels, chemicals and materials is considered as a
There are two types of carbon dioxide-based products
method complementary to carbon dioxide sequestration and
depending on the market size and value: products with high
storing for reducing greenhouse gas emissions, enabling
added value and low market size, such as formic acid, and
carbon dioxide recycling and a more sustainable exploitation
products with low added value and large market volume,
of resources, while reducing costs associated with carbon
Chemical Valorization of CO2 3

such as synthetic fuels and building materials. Fuels have the benefits through the production of saleable products (Zhu
largest potential for carbon dioxide utilization due to their 2019).
huge market volume, while building materials show the A high-technology readiness level (TRL) is an indis-
greatest potential of climate change mitigation mainly pensable requirement for market penetration of the carbon
because of their low energy requirements and permanent dioxide-based products (O’Connell et al. 2019). This chapter
retention of carbon in the product, but face other barriers to focuses on technologies of chemical valorization of carbon
prompt deployment, such as regulations and construction dioxide which are at demonstration level or close to com-
standards (Chauvy et al. 2019; International Energy Agency mercialization, with technology readiness levels higher than
(IEA) 2019; Aresta et al. 2014). In summary, the deployment 5. Moreover, processes of chemical valorization of carbon
of these CO2-based products is limited to about 10 million dioxide which still remain in an early stage of research and
tons of CO2 per year, due to the early stage of development of development are not considered in this chapter. This chapter
some valorization routes, the need for low-carbon, cheap and specifically reviews valorization processes consuming large
renewable energy and hydrogen and the fulfillment of quality volume of carbon dioxide and demonstration projects/plants
standards and regulations (Chauvy et al. 2019; International at pilot or pre-commercial scale. This chapter also highlights
Energy Agency (IEA) 2019; Aresta et al. 2014). the capability of some chemical routes of carbon dioxide
Chemical valorization of carbon dioxide provides also a valorization to integrate renewable energy into the chemical
method for storing the excess of discontinuous renewable and energy infrastructures available for the transport, storage
energy, unable to be discharged into the electricity network, and utilization of the chemicals and fuels synthesized from
in the form of carbon neutral or negative fuels, chemicals carbon dioxide.
and materials, which storing, transport and utilization tech- The present chapter reviews, for each route of chemical
nologies are fully established, contributing to the decar- valorization of carbon dioxide, the maturity, the potential for
bonization of power generation, transportation and other scaling-up, the climatic, economic and environmental ben-
industrial sectors (Centi 2009). efits and the bottlenecks for further development or com-
The development and potential technology transfer of mercialization of the technology and the amount of carbon
processes for the chemical valorization of carbon dioxide to dioxide chemically converted, namely the carbon dioxide
fuels, chemicals and materials would help to overcome the abatement potential, the reduction in carbon and water
limitations to renewable energy deployment, ensure power footprints and in energy consumption as compared with
supplying and lessen the reliance on fossil reserves. conventional production routes, as well as the market size
Chemical valorization of CO2 toward fuels, chemicals and price of the synthesized products.
and materials is a suitable way to provide social wellbeing
and economic growing, while allowing some savings in
greenhouse gas emission, contributing also to the achieve- 2 CO2-Derived Fuels and Chemicals
ment of the environmental, energy and social goals settled at
global and local levels (Ganesh 2014; Goeppert et al. 2014; Carbon dioxide represents an alternative to fossil fuels as a
Centi 2009). source of carbon for the production of platform chemicals,
Presently, only a small number of processes for the transportation fuels or energy carriers, such as methane,
synthesis of valuable products, such as urea, salicylic acid, methanol, ethanol, dimethyl ether, formic acid, carbon
polycarbonates and cyclic carbonates, from carbon dioxide monoxide or syngas, gasoline, diesel and jet fuels. The
are available at commercial scale (Alper and Yuksel Orhan process consists of the reaction of carbon dioxide with
2017; Artz 2018; Fukuoka et al. 2007; Patricio et al. 2017; hydrogen to produce, directly, or indirectly, from the syngas
Quadrelli et al. 2011; Sakakura et al. 2007). Therefore, these generated via the reverse water gas shift reaction, a
technologies will not be reviewed further in this chapter. carbon-containing compound with higher easiness of han-
There are also some innovative technologies for the dling, transport, storage and utilization than pure hydrogen.
conversion of carbon dioxide to various commercial prod- Given that hydrogen production is a highly energy-
ucts, such as chemicals, synthetic fuels, polymers and con- consuming process, low-carbon hydrogen has to be pro-
struction materials, currently at different levels of duced by biomass gasification or reforming coupled with
development and commercialization. The potential applica- carbon dioxide capture and storage, or via electrolysis of
tion of these technologies for the valorization of carbon water powered with renewable or low-carbon electricity
dioxide can result in savings in carbon dioxide emissions, by (International Energy Agency (IEA) 2019). In general, the
improving efficiency, by partially substituting fossil-based cost of hydrogen production dominates the operating cost of
raw materials and by using renewable energy, thus con- the full chemical synthesis process. In summary, carbon
tributing to the decarbonization of power generation and dioxide is a potential raw material for the production of fuels
other industrial sectors and to the creation of economic and chemicals, but its transformation to valuable products
4 E. Ruiz Martínez and J. M. Sánchez Hervás

implies an energy consumption and production costs. mature technologies for the production of fuels and platform
Depending on the carbon dioxide-derived product, the pro- chemicals from CO2.
duction technology has different maturity and potential of
carbon dioxide uptake (Chauvy et al. 2019; International
Energy Agency (IEA) 2019; Agarwal et al. 2011; Álvarez 2.1 Methane
et al. 2017; Götz et al. 2016; HYSYTECH 2020; Jarvis and
Samsatli 2018; Kiss et al. 2016; Made in China 2020; Methane is used to produce heat, electricity and value-added
Panzone et al. 2020; Pérez-Fortes et al. 2016a; Pérez-Fortes chemicals, being an important energy vector. At the indus-
et al. 2016b; Pérez-Fortes and Tzimas 2016; Schmidt et al. trial level, methane is obtained, at relatively low cost, from
2016; Rego de Vasconcelos and Lavoie 2019). fossil natural gas. High-purity methane, also known as
Table 1 shows a non-exhaustive list of the different key substitute natural gas, can be more sustainably produced by
performance indicators, such as TRL of the carbon dioxide methanation of CO2 with renewable hydrogen, generated by
conversion process, production cost and price of the specific electrolysis of water powered by renewable energy, via the
CO2-based product, in kilo euros per ton of synthesized so-called Power-to-Methane process (O’Connell et al. 2019;
product, electricity consumption per ton of synthesized Rego de Vasconcelos and Lavoie 2019).
product, and net carbon dioxide utilization potential, in tons The substitute natural gas produced can be injected
of CO2 utilized per ton of product synthesized, for the most directly into the natural gas grid (Götz et al. 2016). In this

Table 1 Key performance indicators for the most mature technologies for the production of fuels and platform chemicals from CO2
Product CO2 conversion TRL Production Price Electricity CO2 References
process cost (kЄ/t) (kЄ/t) (Mwh/t) utilization
(tCO2/t)
Methane Catalytic 8–9 1.5–13.5 0.92 15.2 2.75 (Chauvy et al. 2019; O’Connell et al.
hydrogenation 2019; Götz et al. 2016; Jarvis and
Samsatli 2018; Panzone et al. 2020;
Behrens et al. 2019; YCharts 2020)
Methanol Catalytic 9 0.5–1.9 0.26 0.55 1.4 (Chauvy et al. 2019; O’Connell et al.
hydrogenation 2019; Jarvis and Samsatli 2018; Kiss
et al. 2016; Panzone et al. 2020;
Pérez-Fortes et al. 2016b; Methanex
2020; Zhang et al. 2019)
Dimethyl Catalytic 6 1.8–2.3 1.6 nda 1.9 (Chauvy et al. 2019; China Petroleum and
ether hydrogenation Chemical Industry Federation 2020;
Michailos et al. 2019; Wulf et al. 2018)
Formic Catalytic 3–5 1.6 0.45– 4.1 0.7 (Álvarez 2017; Jarvis and Samsatli 2018;
acid hydrogenation 0.6 Made in China 2020; Panzone et al. 2020;
Pérez-Fortes et al. 2016a; Rego de
Vasconcelos and Lavoie 2019)
Electrochemical 5–6 0.85 0.45– 1.1 0.5 (Chauvy et al. 2019; Agarwal et al. 2011;
reduction 0.6 HYSYTECH 2020; Pérez-Fortes and
Tzimas 2016; Rego de Vasconcelos and
Lavoie 2019)
Ethanol Syngas 9 0.8 0.98 nda 1.9 (Chauvy et al. 2019; O’Connell et al.
fermentation 2019; Global Petrol Prices 2020; Handler
et al. 2016; Medeiros et al. 2020)
Liquid Reverse Water 8–9 0.5–2 0.27– 6.8 2.6 (O’Connell et al. 2019; Jarvis and
fuels: Gas 0.32 Samsatli 2018; Schmidt et al. 2016)
gasoline, Shift + Fischer
diesel, Tropsch
kerosene
This table summarizes the different key performance indicators, such as TRL of the carbon dioxide conversion process, production cost and price
of the specific CO2-based product and electricity consumption and net carbon dioxide utilization potential in product formation, for the most
mature technologies for the production of fuels and platform chemicals from carbon dioxide. Comparison of key performance indicators of
different alternative technologies gives an idea of the most advantageous and advanced technology for the production of a given carbon
dioxide-based product.
TRL Technology Readiness Level, nda no data available.
Chemical Valorization of CO2 5

way, substitute natural gas can be exploited immediately share of renewable energy, initiated research and develop-
using the currently available natural gas storage, transport ment projects focused on Power-to-Methane technology
and utilization infrastructures, minimizing the investment (Rego de Vasconcelos and Lavoie 2019). The
needed for massive deployment of CO2 methanation tech- Power-to-Methane technology is currently in an advanced
nology (Navarro et al. 2018). Power-to-Methane technology stage of development leading to a technology readiness level
constitutes a promising pathway for large-scale and of up to 8–9 (O’Connell et al. 2019; Behrens et al. 2019).
long-term renewable energy storage while reducing green- Several Power-to-Methane pilot and demonstration
house gas emissions. Power-to-Methane technology allows plants, both using catalytic and biological methanation, are
interconnecting the gas and electrical networks, resulting in a already in operation in different countries, and others are still
great flexibility to the balance of the energy grid (Bailera being developed. Most of the Power-to-Methane plants are
et al. 2017). installed in Europe. A non-exhaustive list of plants or pro-
CO2 methanation can be catalytic or biological. The jects for Power-to-Methane is provided in Table 2 (Zhu
biological methanation is carried out by fermentation of CO2 2019; O’Connell et al. 2019; Götz et al. 2016; Rego de
in the biogas plant itself or in a detached bioreactor Vasconcelos and Lavoie 2019; Wulf et al. 2018; Bailera
(O’Connell et al. 2019). Catalytic CO2 methanation is most et al. 2017; Thema et al. 2019). This table combines and
usually carried out over nickel-based catalysts due to their updates earlier reviews by Zhu (2019), O’Connell et al.
high activity and low cost (Behrens et al. 2019; Ghaib and (2019), Götz et al. (2016), Rego de Vasconcelos and Lavoie
Ben-Fares 2018) at temperatures between 200 and 550 °C, to (2019), Wulf et al. (2018), Bailera et al. (2017) or Thema
avoid potential formation of highly toxic nickel carbonyls at et al. (2019), adding previously un-reviewed projects or
200 °C and deactivation of catalyst by sintering and coking plants and including details such as plant operational status,
at temperatures above 550 °C (Schaaf et al. 2014) and at city and country of location of the plant, type of conversion
moderate pressures (1–100 bar) (Götz et al. 2016; Rego de technology of carbon dioxide, technology readiness level,
Vasconcelos and Lavoie 2019). CO2 source, plant capacity, expressed in terms of total
Since methanation reaction is exothermal, the increment methane output in Nm3/h and installed power in kW cal-
of temperature in the reactor may result in equilibrium culated from the lower heating value of methane product
limitations in conversion and hydrothermal deactivation of gas, as well as main references.
the catalyst (Götz et al. 2016). Therefore, different config- In most of the plants the CO2 is sourced from biogas
urations of reactor, such as three-phase, heat exchanger, upgrading or from CO2 fraction in biogas streams. In some
fixed bed, fluidized bed and structured, are used to improve plants the CO2 is obtained from flue gas or industrial
the performance of the methanation process (Rego de Vas- emissions. A few plants use CO2 directly captured from air
concelos and Lavoie 2019). Basically, there are two different (O’Connell et al. 2019).
methanation reactor concepts: fixed bed reactor with inter- In early 2019, substitute natural gas production capacity
mediate cooling steps, developed by TREMP/Haldor- was about 6–7 MW of methane, according to the capacity of
Topsoe, Hicom/British Gas Corp, RMP/Ralph, Lurgi and the plants of Power-to-Methane being in operation mostly in
Sasol/Lurgi GmbH reactors, and fluidized bed reactor, Europe (O’Connell et al. 2019; Thema et al. 2019). For some
developed by Comflux/Thyssengas GmbH and plants, the capacity is unknown. In addition, some plants are
Bi-Gas/Bituminous Coal Res reactors (Schaaf et al. 2014). announced, planned, projected or under construction.
Other reactor concepts have also been brought to market, Therefore, the estimated substitute natural gas production
such as catalytic wall tubular reactor and parallel plate capacity would be actually higher than 16 MW of CH4
reactor (Schaaf et al. 2014). New reaction systems have also (O’Connell et al. 2019). The European natural gas grid
been investigated to enable better temperature control, such consists of a more than 2 million km transport and distri-
as suspended reactor, also known as “slurry-phase bution network and approximately 800 TWh of underground
bubble-column reactor”, magnetic fluidized bed reactor, storage through Europe (Behrens et al. 2019), available to
dielectric barrier discharge plasma reactor and micro-channel absorb the potential substitute natural gas production.
reactor, which can inspire new developments of industrial Power-to-Methane technology can contribute to fulfill the
methanation reactors (Gao et al. 2015). There are also some requirements of long-term and massive storage of fluctuating
commercial Ni-based catalysts for substitute natural gas renewable energy, resulting in a significant demand of
production with high efficiency, lifetime, poison resistance Power-to-Methane plants in the future (O’Connell et al.
and thermal stability, developed, among others, by Johnson 2019). Extrapolation to the electricity demand of the Euro-
Mathey (CRG), Haldor-Topsoe (PK-7R) and CLARIANT pean Union leads to about 25 GW of methane (O’Connell
(METH130/134/135). et al. 2019). Furthermore, renewable transportation fuels are
Different countries, especially in Europe, driven by the also required in the European Union to achieve the target
need to reduce greenhouse gas emissions and intensify the reduction of greenhouse gas emissions. The final methane
6 E. Ruiz Martínez and J. M. Sánchez Hervás

Table 2 Plants or projects for Power-to-Methane in Europe


Plant/project Status Location Capacity Tec TRL CO2 source References
Nm3/h
(kW) CH4
Audi e-gas In operation Werlte (DE) 320 (3184) Cat 7 Biogas (Zhu 2019; O’Connell
upgrading et al. 2019; Götz et al.
2016; Rego de
Vasconcelos and Lavoie
2019; Wulf et al. 2018;
Bailera et al. 2017; Thema
et al. 2019; Kondratenko
et al. 2013)
ETOGAS ZSW In operation Stuttgart (DE) 12.5 (124) Cat 6 nda (Zhu 2019; O’Connell
et al. 2019; Rego de
Vasconcelos and Lavoie
2019; Wulf et al. 2018;
Bailera et al. 2017; Ghaib
and Ben-Fares 2018;
Zentrum für
Sonnenenergie-und
Wasserstoff-Forschung
Baden-Württemberg
(ZSW) 2020)
CoSin In operation Barcelona (ES) 10 (41) Cat 6 Biogas (O’Connell et al. 2019;
upgrading Naturgy 2020; Guilera
et al. 2020)
P2G Rozenburg In operation Rozenburg (NL) 2 (2.75) Cat 6 nda (O’Connell et al. 2019;
Wulf et al. 2018; Bailera
et al. 2017; Thema et al.
2019; Vlap et al. 2015)
Stromspeicherung Planned/announced Wunsiedel (DE) 7960 Cat Flue gas (O’Connell et al. 2019)
Wunsiedel
BioPower2Gas In operation Allendorf (DE) 60–220 Bio 6 Biogas (O’Connell et al. 2019;
(149) upgrading Wulf et al. 2018; Bailera
et al. 2017; Thema et al.
2019; BioPower2Gas
2016; Müller et al. 2017)
P2G BioCat In operation Avedore (DK) 200 (1990) Bio 7 CO2 fraction in (O’Connell et al. 2019;
biogas Götz et al. 2016; Rego de
Vasconcelos and Lavoie
2019; Wulf et al. 2018;
Bailera et al. 2017; Thema
et al. 2019; BioCat Project
2016)
DemoSNG In operation Köping (SE) Nda Cat 6 Biomass (O’Connell et al. 2019;
gasification Rego de Vasconcelos and
syngas /flue gas Lavoie 2019; Bailera et al.
2017; Thema et al. 2019)
Jupiter 1000 Under construction Fos sur mer (FR) 25 (249) Cat 7 Industrial (O’Connell et al. 2019;
emission from Wulf et al. 2018; Thema
an et al. 2019; Jupiter 1000
ASCOMETAL 2019)
factory
EXYTRON In operation Rostock (DE) 1 (10) Cat 7 Flue gas (O’Connell et al. 2019;
Wulf et al. 2018; Thema
et al. 2019; Müller et al.
2017)
(continued)
Chemical Valorization of CO2 7

Table 2 (continued)
Plant/project Status Location Capacity Tec TRL CO2 source References
Nm3/h
(kW) CH4
Eichhof In operation Bad Hersfeld (DE) 20 (199) Cat 6 CO2 fraction in (O’Connell et al. 2019;
biogas Wulf et al. 2018; Thema
et al. 2019)
RAG Planned Pilsbach (AT) (10,000) Bio 6 nda (O’Connell et al. 2019;
underground-sun-conversion Underground Sun
Conversion 2020)
STORE & GO In operation Falkenhagen (DE) 57 (567) Cat 7 Bioethanol (O’Connell et al. 2019;
plant (biogas) Rego de Vasconcelos and
Lavoie 2019; Wulf et al.
2018; Bailera et al. 2017;
Thema et al. 2019; Store &
Go 2020)
STORE & GO In operation Solothurn (CH) 11.5 (114) Bio 7 Waste water (O’Connell et al. 2019;
treatment plant Rego de Vasconcelos and
Lavoie 2019; Wulf et al.
2018; Bailera et al. 2017;
Thema et al. 2019; Store &
Go 2020; Hafenbradl 2017)
STORE & GO In operation Puglia–Troia (IT) 11 (100) Cat 7 Air capture (O’Connell et al. 2019;
Rego de Vasconcelos and
Lavoie 2019; Wulf et al.
2018; Bailera et al. 2017;
Thema et al. 2019; Store &
Go 2020)
Energiepark In operation Pirmasens-Winzeln 50 (498) Bio 7 CO2 fraction in (O’Connell et al. 2019;
(DE) biogas Wulf et al. 2018; Thema
et al. 2019)
Energiepark extension In operation Pirmasens-Winzeln (996) Bio 7 CO2 fraction in (O’Connell et al. 2019;
(DE) biogas Thema et al. 2019;
Prüf-und
Forschungsinstitut
(PFI) Germany 2020)
Hybridge (AMPRION, Announced Southern Emsland (100,000) nda nda nda (O’Connell et al. 2019;
OGE) (DE) (electrolyzer) Thema et al. 2019; Wiede
and Land 2018)
CO2-SNG In operation Laziska Görne (PL) 4.5 (45) Cat 6 Flue gas (Wulf et al. 2018; Bailera
et al. 2017; Chwoła 2020)
Power to gas Hungary Projected nda (HU) (10,000) Bio 7–8 nda (Wulf et al. 2018; Thema
(electrolyzer) et al. 2019; Bertalan and
Hein 2016)
Symbio In operation Lyngby (DK) nda Bio 6 nda (Wulf et al. 2018; Bailera
et al. 2017; Thema et al.
2019; Technical University
of Denmark (DTU) 2013)
Swisspower Planned/Under Dietikon (CH) * 200,000 Bio nda Waste water (Wulf et al. 2018; Thema
Hybridkraftwerk construction treatment plant et al. 2019; SolarServer
2020; Swisspower 2020)
Greenlab Skive Planned Skive Kåstrup (DK) (10 MW Cat 6 nda (Wulf et al. 2018; Winther
methanol) Mortensen et al. 2019;
Danish Energy Agency
(DEA) 2020; State of
Green 2019)
Exytron Projected Alzey (DE) 2.5 Cat 7–8 nda (Wulf et al. 2018; Thema
Zero-Emission-Wohnpark et al. 2019)
(continued)
8 E. Ruiz Martínez and J. M. Sánchez Hervás

Table 2 (continued)
Plant/project Status Location Capacity Tec TRL CO2 source References
Nm3/h
(kW) CH4
Power-to-Flex Planned (NL-DE) nda Bio 6–7 nda (Wulf et al. 2018; Thema
et al. 2019)
MeGa-stoRE 2 In operation Heden (DK) 60 Bio 6 nda (Wulf et al. 2018; Thema
et al. 2019; Danish Gas
Technology Centre
(DGC) 2017)
Power to Gas Biogasbooster nda Straubing (DE) 0.4 (40) Bio 6 nda (Wulf et al. 2018; Thema
et al. 2019)
IET Rapperswil nda Rapperswil (CH) Pilot Cat 6 Air (Wulf et al. 2018; Thema
et al. 2019; Institut fur
Energietechnik (IET) 2017)
Infinity 1 Under construction Pfaffenhofen (DE) * 70 (700) Bio 7 Waste water (Wulf et al. 2018; Thema
(starting up 2020) treatment plant et al. 2019; Nagengast
2017)
MeGa-stoRE com 1 Planned nda (DK) 10,000,000 Cat nda nda (Thema et al. 2019; Biogas
(electrolyzer) 2015)
MeGa-stoRE com 2 Planned nda (DK) 10,000,000 Cat nda nda (Thema et al. 2019; Biogas
(electrolyzer) 2015)
This table compiles Power-to-Methane pilot and demonstration plants or projects currently in operation, announced, planned, projected or under construction
in Europe, as reported in literature. This table includes details about plant operational status, city and country of location of the plant, type of methanation
technology, technology readiness level, CO2 source and plant capacity, which give an idea of the level of development, deployment and sustainability of
methanation technologies and the substitute natural gas production capacity thorough Europe.
Tec Technology, TRL Technology Readiness Level, nda no data available, DE Germany, Catcatalytic, ZSW Zentrum für Sonnenenergie- und
Wasserstoff-Forschung Baden-Württemberg, nda no data available, ES Spain, P2G Power-to-Gas, NL Netherlands, Bio biological, DK Denmark, SE
Sweden, FR France, AT Austria, CH Switzerland, IT Italy, PL Poland, HU Hungary, NL-DE Dutch-German collaboration, IET Institut fur Energietechnik

demand for road, rail, aviation and navigation vehicles will water electrolysis dominates both the capital expenditure and
strongly depend on the level of electrification and on the fuel operating cost for CO2 catalytic methanation, which ranges
mix of the future scenario of vehicles (O’Connell et al. 2019). between 35.8 and 38.8 M€ and 0.6−0.9 €/kWh, respec-
More specifically, the techno-economic and environ- tively, for a substitute gas natural production rate of nearly
mental viability, industrial applicability and profitability of 311 m3/h and a plant operational lifetime of 20 years (Götz
the CO2 catalytic methanation technology are limited by the et al. 2016; Jarvis and Samsatli 2018). Therefore, consider-
lack of availability of cheap and renewable hydrogen and ing a low heating value of methane of about 9.95 kWh/m3, a
electricity (Jarvis and Samsatli 2018). The greenhouse gas net capital expenditure of about 918–994 €/tCH4 and a net
mitigation capacity of CO2 catalytic methanation technology operational cost around 8338–12,507 €/tCH4 can be esti-
is conditioned by the fact that the required hydrogen and mated. Other techno-economic studies estimated a methane
electricity come from renewable and carbon neutral or production cost between 1500 and 6800 €/tCH4 depending
negative sources (Jarvis and Samsatli 2018). According to on the type of Power-to-Methane technology and carbon
Artz et al. (2018), in a best-case scenario, carbon dioxide dioxide source utilized (Panzone et al. 2020). The product
emissions can be reduced by up to 87% for CO2 methanation price for substitute natural gas is assumed to be equal to the
as compared to conventional production routes (Artz et al. current European Union natural gas import price of about
2018). 924 €/tCH4 (YCharts 2020). Therefore, the financial via-
The estimated net CO2 utilization for the catalytic metha- bility of the Power-to-Methane technology is still lacking
nation process is about 2.75 tCO2/tCH4. Considering a under the present conditions.
global methane production capacity of about 1100–1500 Power-to-Methane technology could play an important
MtCH4/y, the potential for CO2 uptake ranges between 3000 role in the future energy system, although there are still a
and 4000 MtCO2/y (Chauvy et al. 2019). number of technical and economic barriers, such as low
The estimated electricity consumption of the catalytic efficiency and high costs, which need to be successfully
methanation process is about 15.2 MWh/tCH4 (Götz et al. resolved prior to its commercialization. In the case of cat-
2016; Jarvis and Samsatli 2018). Hydrogen production from alytic methanation of CO2, pending research areas include:
Chemical Valorization of CO2 9

addressing catalyst robustness under intermittent and natural gas, called “low-carbon methanol”, by injecting
unsteady-state operation; exploring compact, efficient and waste CO2 into the methanol production process (Hobson
intensified methanation reactors suitable for fluctuating and Márquez 2018). There are also several research and
operating conditions, such as plate reactors, micro-reactors development projects which focus on low-carbon methanol
and milli-reactors and sorption-enhanced and membrane synthesis from renewable energy and CO2-containing syn-
reactors; acquiring more information on the operation gas, such as Carbon2Chem in Germany and FRESME in
dynamics of the methanation reactors to define the size of Sweden (Hobson and Márquez 2018).
the hydrogen storage; optimization, control and management Methanol can also be produced, more sustainably, by
of the heat release during methanation reaction to minimize hydrogenation of recycled carbon dioxide with hydrogen
carbon deposition, prevent formation of toxic nickel car- produced by water electrolysis using renewable electricity,
bonyls and increase the energy efficiency of the overall via the Power-to-Methanol process (Centi 2009; Rego de
Power-to-Methane process; and development of new cata- Vasconcelos and Lavoie 2019; Ali et al. 2015; Saeidi et al.
lysts with high activity and poison tolerance at lower tem- 2014; Sankaranarayanan and Srinivasan 2012; Ham et al.
peratures (200–300 °C) and with high mechanical strength 2012).
and hydrothermal stability at high temperature (above 550 ° Renewable methanol production, via the Power-to-
C), given the high exothermicity of the reaction (Götz et al. Methanol process, can avoid investment for energy storage
2016; Rego de Vasconcelos and Lavoie 2019; Behrens et al. and distribution, absorb and transform the excess of elec-
2019; Schaaf et al. 2014; Gao et al. 2015; Centi et al. 2013; tricity and hydrogen into valuable chemicals and fuels in a
Hu and Urakawa 2018; Mutz et al. 2015). competitive and efficient way and reduce carbon dioxide
The European demonstration projects currently running emissions associated with industry and transportation (Ber-
will supply the basis for planning full-size installations by gins et al. 2015).
providing information on long-term performance, opera- Methanol can be synthesized directly from CO2, or in two
tional limitations and flexibility of methanation systems steps, indirectly from intermediate syngas via the reverse
(Behrens et al. 2019; Bailera et al. 2017). water gas shift reaction.
The CAMERE process for carbon dioxide hydrogenation
via the reverse water gas shift reaction was developed to a
2.2 Methanol pilot plant level of 100 kg CH3OH/d by the Korean Institute
of Science and Technology in Korea (Joo et al. 1999).
Methanol has a relatively high energy density, of about 4.4 The hydrogenation of carbon dioxide directly to methanol
kWh/dm3, and octane rating, of around 110, storage stabil- occurs at 250–300 °C and 50–100 bars over same
ity, easiness of handle and transport and established usage copper-based industrial catalyst modified with different
(Rego de Vasconcelos and Lavoie 2019; Onishi et al. 2018). additives and promoters (Behrens et al. 2019; Centi et al.
Methanol has a big potential as an energy, fuel or hydrogen 2013; Saeidi et al. 2014; Jadhav et al. 2014; Ma et al. 2009;
liquid carrier (Behrens et al. 2019). Methanol can be utilized Wang et al. 2011; Yan et al. 2014).
for power generation directly, in methanol fuel cells, or Direct CO2 hydrogenation technology for methanol pro-
indirectly, after conversion to hydrogen or gasoline, duction can be considered almost ready to be commercial-
respectively, in fuel cells or in internal combustion engines ized (Centi 2009; O’Connell et al. 2019; Behrens et al. 2019;
(Ganesh 2014; Goeppert et al. 2014; Al-Saydeh and Zaidi Wilson et al. 2015). According to O’Connell et al. (2019),
2018). Power-to-Methanol technology has already been developed
Methanol is also an important feedstock material for the to a technology readiness level of nearly 9 (O’Connell et al.
fabrication of different chemical intermediates and industrial 2019). The technical feasibility of the technology was firstly
products, such as olefins, dimethyl ether, aromatics, liquid confirmed, at the pilot plant level of 100 tCH3OH/y, by
fuels, paint and polymers, becoming a clean and Mitsui Chemicals Osaka Works in Japan, using an own
cost-competitive alternative to fossil fuels (Ganesh 2014; developed catalyst (Sankaranarayanan and Srinivasan 2012;
Goeppert et al. 2014; Behrens et al. 2019; Dang et al. 2019). Huang 2014). At the industrial level, the first plant for
On an industrial scale, methanol is currently synthesized production of methanol from carbon dioxide was the George
from CO2-containing syngas, obtained mainly by natural gas Olah plant, implemented by Carbon Recycling International
reforming, using catalysts consisting of copper, zinc oxide in Iceland (Kondratenko et al. 2013; Sankaranarayanan and
and alumina (Kondratenko et al. 2013; Olah et al. 2009). In Srinivasan 2012; Huang 2014). However, compared to
recent years, different companies, such as Methanex in commercial technology to obtain methanol from CO, direct
Canada and Qatar Fuel Additives Company Limited CO2 hydrogenation suffers from higher consumption of
(QAFAC) in Qatar, have implemented technologies that hydrogen and lower productivity (Kondratenko et al. 2013).
reduce the carbon footprint of methanol synthesized from Today, some companies, such as Süd-Chemie Mitsubishi
10 E. Ruiz Martínez and J. M. Sánchez Hervás

Gas Chemical, Sinetix, Ceramatec and Haldor-Topsoe, are target reduction of greenhouse gas emissions. The final
commercializing highly active and stable catalysts for methanol demand for road, aviation, rail and navigation
methanol production by CO2 hydrogenation (Kondratenko vehicles will strongly depend on the level of electrification
et al. 2013; Al-Saydeh and Zaidi 2018). and transportation fuel mix of the future scenario of vehicles
Until now, only a few Power-to-Methanol plants are (O’Connell et al. 2019).
currently operational and projects targeting at constructing The estimated net CO2 utilization of Power-to-Methanol
pilot and demonstration plants are in progress, especially in process is about 1.4 tCO2/tCH3OH (Chauvy et al. 2019;
Europe, driven by the need to reduce greenhouse gas Jarvis and Samsatli 2018; Kiss et al. 2016). Considering an
emissions and intensify the share of renewable energy installed global production capacity of methanol of about
(O’Connell et al. 2019; Rego de Vasconcelos and Lavoie 110 million ton of methanol per year (Methanol Institute
2019; Al-Saydeh and Zaidi 2018). A non-exhaustive list of 2020), the potential of CO2 utilization is about 154 million
Power-to-Methanol plants and projects is provided in tons of carbon dioxide per year. Direct CO2 hydrogenation
Table 3 (Zhu 2019; O’Connell et al. 2019; Rego de Vas- to methanol emits about 0.226 tCO2/t methanol, while
concelos and Lavoie 2019; Behrens et al. 2019; Wulf et al. conventional methanol synthesis releases 0.768 tCO2/
2018; Bailera et al. 2017; Al-Saydeh and Zaidi 2018; Hob- tCH3OH (Pérez-Fortes et al. 2016b). Therefore, the net
son and Márquez 2018). This table combines and updates amount of CO2 avoided by the Power-to-Methanol process
earlier reviews by Zhu (2019), O’Connell et al. (2019), Rego is about 2 tCO2/tCH3OH (Jarvis and Samsatli 2018).
de Vasconcelos and Lavoie (2019), Behrens et al. (2019), According to Artz et al. (2018), in a best-case scenario,
Wulf et al. (2018), Bailera et al. (2017); Al-Saydeh and Zaidi carbon dioxide emissions can be reduced by up to 93% for
(2018) or Hobson and Márquez (2018) adding previously Power-to-Methanol process as compared to conventional
un-reviewed projects and including details such as plant production routes (Artz et al. 2018).
operational status, city and country of location of the plant, The electricity needed for methanol synthesis by direct
technology readiness level, CO2 source, plant capacity, CO2 hydrogenation is about 170 kWh/tCH3OH, but can
expressed in terms of total methanol production, in t/y, and reach up to 550 kWh/tCH3OH if hydrogen production by
installed power in kW, calculated from the lower heating water electrolysis is integrated (Kiss et al. 2016). Therefore,
value of methanol product, as well as main references. powering the CO2 hydrogenation with electricity from
In most of the plants, the CO2 is sourced from waste renewable sources is indispensable to keep a neutral or
gases of power plants and industrial processes. A few plants negative carbon balance for the process (Jarvis and Samsatli
use CO2 captured directly from air. 2018).
According to the size of Power-to-Methanol plants cur- Methanol production by CO2 hydrogenation results also
rently in operation in Europe (see Table 3), methanol pro- in a low water footprint compared to conventional methanol
duction capacity is about 4300 tCH3OH/y or nearly 3 MW production from syngas, each with a consumption of water
of methanol, according to the methanol low heating value of about 26.4 tH2O/tCH3OH and 90 tH2O/tCH3OH, corre-
(O’Connell et al. 2019). The capacity of some plants is spondingly (Jarvis and Samsatli 2018).
unknown. In addition, some plants are, announced, planned, According to a study by Pérez-Fortes et al. (2016b), the
projected or under construction. Therefore, the estimated capital expenditure and annual operating and maintenance
methanol production capacity could be actually higher. cost for a carbon dioxide hydrogenation to methanol plant
Methanol is one of the most important materials in the were about 200 and 293 million euros, respectively, con-
worldwide chemicals and energy markets with a continu- sidering an annual plant production capacity of 440,000 tons
ously growing demand (Jadhav et al. 2014). Global metha- of renewable methanol and a plant operational lifetime of
nol annual demand is approaching 100 million tons in 2020 20 years (Jarvis and Samsatli 2018; Pérez-Fortes et al.
(Methanol Institute 2020). Methanol synthesized from CO2 2016b). A net capital cost of about 23 €/tCH3OH and a net
can be used to produce almost all industrial products that are operational cost of around 666 €/tCH3OH were assessed,
currently derived from fossil fuels, leading to the same each slightly lower and considerably higher than for a con-
associated demand. ventional syngas-based plant, respectively (Pérez-Fortes
The methanol demand will potentially expand even fur- et al. 2016b). In accordance with a recent study by Zhang
ther in the future, as the use of methanol as energy, hydrogen et al. (2019), the total cost associated with methanol pro-
and fuel vector increases. In fact, Power-to-Methanol tech- duction by CO2 hydrogenation with integrated solid-oxide
nology would contribute to fulfill the requirements of electrolyzer was about 500 €/tCH3OH, considering an
long-term and massive renewable energy storage, resulting annual plant production capacity of 100,000 tons of
in a significant demand of Power-to-Methanol plants in the renewable methanol (Zhang et al. 2019). Other
future (O’Connell et al. 2019). Furthermore, renewable techno-economic studies estimated a methanol production
transportation fuels are also needed in the EU to achieve the cost between about 500 and 1900 €/tCH3OH, depending on
Chemical Valorization of CO2 11

Table 3 Plants or projects for Power-to-Methanol


Plant/project Status Location Capacity t/y TRL CO2 source References
(kW) CH3OH
Greenfuel In operation Essen (DE) 0.91 4–5 Air captured (O’Connell et al. 2019; Kanacher and
Innogy 2017)
George Olah Plant In operation Svartsengi (IS) 4000 7–8 Flue gas (Zhu 2019; (O’Connell et al. 2019;
(*2500) geothermal Rego de Vasconcelos and Lavoie
power plant 2019; Wulf et al. 2018; Al-Saydeh
and Zaidi 2018)
MefCO2 Under Niederaussem 1 t/d (*230) 6 Flue gas of (O’Connell et al. 2019; Rego de
construction (DE) power plant Vasconcelos and Lavoie 2019;
Behrens et al. 2019; Wulf et al. 2018;
MefCO2 2020; Europe 2020a; Spire
2030 2020; Cuesta Pardo and Everis
2018; Kourkoumpas et al. 2016)
FResMe Planned Luleå (SE) 2.5 t/d 6 Steel plant (O’Connell et al. 2019; Cuesta Pardo
(*2019) (*575) gases and Everis 2018; Fresme project
2017; Bonalumi et al. 2018; Europe
2020b; Energy research Centre of the
Netherlands (ECN) 2017)
E2fuels Planned Haßfurt (DE) (507) nda nda (O’Connell et al. 2019; Albert J,
Chemical Reaction Engineering
(CRT) University of
Erlangen-Nuremberg 2020)
E-CO2MET Planned Leuna (DE) MW scale nda Industrial (Knowledge Energy Institute
concentrated (KEI) 2019; TOTAL 2019; News
CO2 from Green Hydrogen 2019)
refinery
Power-to-Methanol Announced Lillo (BE) 8000 nda Captured (O'Reilly 2020; Taylor 2020; Friis M,
Antwerp BV (*5000) CO2 Blue World Technologies 2019)
Power2Met phase Planned Aalborg (DK) * 198 nda nda (Friis M, Blue World Technologies
1- Aalborg (*2019) (*124) 2019; Søren 2020; Hydrogen Valley
university 2020)
Power2Met phase 2 Planned nda (DK) * 791– nda Biogas plant (Friis M, Blue World Technologies
(*2020-) 1,582 2019; Søren 2020; Hydrogen Valley
(*495–991) 2020)
Power2Met phase 3 Planned North Jutland * 1.1 t/h nda nda (Friis M, Blue World Technologies
(*2022–) main power (*6000) 2019; Søren 2020; Hydrogen Valley
plant (DK) 2020)
BASF/BSE Projected nda (DE) 1.55 t/h 7 Flue gas (Zhu 2019; Wulf et al. 2018;
(8587) Bartmann and Wranik 2017;
Schweitzer C- bse Engineering 2017)
Silicon Fire (SLF) In operation Altenrhein, 33 kg/h 6 nda (O’Connell et al. 2019)
Kanton St. (*183)
Gallen (CH)
Silicon Fire (SLF Planned nda (CH) 12 t/d (2770) 9 Biogenic or (O’Connell et al. 2019; Swiss Liquid
15) waste-CO2 Future 2016)
Carbon2Chem In operation Duisburg (DE) nda 6–7 Steel plant (Hobson and Márquez 2018; Bender
gases and Thyssenkrupp 2018; Fona 2016)
Haldor-Topsoe Announced Foulum (DK) 10 kg/h (55) nda Biogas (Ravn and Haldor-Topsoe 2019)
This table compiles Power-to-Methanol pilot and demonstration plants or projects currently in operation, announced, planned or under construction
in Europe, as reported in literature. This table includes details about plant operational status, city and country of location of the plant, technology
readiness level, CO2 source and plant capacity, which give an idea of the level of development, deployment and sustainability of
Power-to-Methanol technology and the renewable methanol production capacity thorough Europe.
TRL Technology Readiness Level, DE Germany, IS Iceland, SE Sweden, nda no data available, BE Belgium, DK Denmark, SLF Swiss Liquid
Future, CH Switzerland.
12 E. Ruiz Martínez and J. M. Sánchez Hervás

the type of electrolysis technology and carbon dioxide kinetics with reduced residence time and reactor size (Ham
source utilized (Panzone et al. 2020). According to Metha- et al. 2012; Jadhav et al. 2014; Wang et al. 2011).
nex Corporation, the market price for methanol is currently A two-stage fixed bed reactor design also enables a smoother
260 euros per ton of methanol (Methanex 2020). Therefore, temperature profile along the length of the tube and increases
direct CO2 hydrogenation is not yet commercially compet- catalyst lifetime and activity (Jadhav et al. 2014; Ma et al.
itive to industrial syngas route for methanol production, due 2009). Another system studied is a reactor consisting of
to the low price of methanol. two stages with two types of membranes: one selective to
Power-to-Methanol technology could play a crucial role hydrogen and one to water, the so-called dual-type perm-
in chemical industry and energy system in the future. The selective membrane reactor. The dual-type perm-selective
current technological challenges include increasing energy membrane reactor allows overcoming the limitation of
efficiency while reducing the cost of the carbon dioxide thermodynamic equilibrium, improving kinetically limited
hydrogenation process. Clearly, the development of novel reactions and controlling the hydrogen to carbon dioxide
catalysts and process designs is needed to accelerate wide- ratio in the reactor feed (Wang et al. 2011).
spread penetration of greener CO2 to methanol processes.
Some commercial catalysts are already available for the
carbon dioxide hydrogenation process, but there are still a 2.3 Dimethyl Ether
number of opportunities to improvement (Centi 2009;
Kondratenko et al. 2013; Sankaranarayanan and Srinivasan Dimethyl ether is a gas at ambient temperature and pressure,
2012; Ma et al. 2009; Yan et al. 2014), such as: increase but liquefies by slight compression or cooling, making
conversion to methanol at low temperature by using the dimethyl ether ease to transport and storage. Dimethyl ether
Cu/ZnO/Al2O3 catalyst promoted with ZrO2, La2O3, Ga2O3 is a potential substitute for liquefied petroleum gas in
and SiO2 (Kondratenko et al. 2013; Ali et al. 2015; Saeidi domestic, transportation and industrial applications. Due to
et al. 2014; Sankaranarayanan and Srinivasan 2012; Ham its good ignition features and relatively high cetane number,
et al. 2012; Ma et al. 2009; Wang et al. 2011; Yan et al. around 55–60 versus 40–55 for diesel, dimethyl ether can be
2014; Huang 2014), the use of catalysts based on Pd or Ag burned, with negligible modifications, in compression igni-
supported on ZnO, ZrO2, MCM-41 and SBA-15, to improve tion engines as an alternative to conventional diesel fuel for
tolerance to inhibition by water, with alkali promoters, to transportation, power generation and household applications.
increase the conversion, or on carbon nanotubes, to improve In addition, the combustion of dimethyl ether leads to lower
selectivity (Ali et al. 2015; Ham et al. 2012; Ma et al. 2009; emission of pollutants, such as nitrogen oxides, sulfur
Wang et al. 2011; Yan et al. 2014), or on metal carbides, compounds, soot and carbon monoxide, than conventional
such as TiC, Mo2C, Fe3C, SiC and TaC, to improve activity, fuels. Dimethyl ether can also be transformed into olefins
selectivity and resistance to deactivation (Ma et al. 2009; and hydrocarbons (Álvarez et al. 2017; Li et al. 2018; Wang
Yan et al. 2014). et al. 2009).
Water generated in the carbon dioxide hydrogenation Commercially, dimethyl ether is obtained by catalytic
reaction inhibits the formation of methanol and cause dehydration of methanol. One-step synthesis of dimethyl
hydrothermal deactivation of catalyst incremented by the ether from synthesis gas reached the demonstration level at a
exothermicity of the reaction (Centi et al. 2013; Ali et al. 100 t/d plant in JFE Steel Corporation in Japan (Olah et al.
2015; Sankaranarayanan and Srinivasan 2012; Ma et al. 2009; Yotaro et al. 2006).
2009; Wang et al. 2011). Korea Gas Co. (KOGAS) has developed a proprietary
There are also opportunities for optimizing reactor catalyst and a process for the synthesis of dimethyl ether
design, such as the development of fluidized bed membrane from syngas derived from the tri-reforming of methane,
reactors with water-cooled walls and two-stage reactors with CO2, and H2. KOGAS demonstrated the indirect synthesis of
intermediate cooling to reduce hydrothermal deactivation dimethyl ether on a scale of 10 tDME/y. KOGAS has still to
and extending lifetime of the catalysts and recirculation of commercialize its dimethyl ether production process due to a
the feed for getting higher conversions while improving heat lack of economic viability (Chung et al. 2012).
transfer in the reactor (Saeidi et al. 2014). Another possi- Dimethyl ether can be also produced by direct hydro-
bility to improve reaction system is the development of genation of carbon dioxide with renewable hydrogen over
membrane reactors for the separation of water from the bi-functional catalysts combining an active catalyst for the
reaction medium to shift the equilibrium to the product side, synthesis of CH3OH from CO2, such as CuO-ZnO-Al2O3 or
with the consequent increase in methanol production while CuO-TiO2, and an acid catalyst for dehydration of CH3OH
reducing reagent consumption, facilitating operation at lower to dimethyl ether, such as Al2O3 or zeolites, in the same
pressures and higher temperatures, preventing catalyst inhi- fixed bed or suspended reactor (Álvarez et al. 2017; Centi
bition and deactivation by water and promoting reaction et al. 2013; Wang et al. 2011, 2009; Li et al. 2018; Naik
Chemical Valorization of CO2 13

et al. 2011). Optimization of catalysts for CO2 hydrogena- by direct CO2 hydrogenation is currently not competitive as
tion to dimethyl ether in a one step includes the addition of compared with dimethyl ether derived from fossil.
promoters to increase the production of dimethyl ether, such The estimated net CO2 utilization of the direct CO2
as Pd and MoO3, the selectivity to dimethyl ether, such as hydrogenation to dimethyl ether process is about 1.9 tCO2/
Ga2O3 and Cr2O3, and the lifetime of the catalyst, such as tDME (Chauvy et al. 2019). Therefore, considering a global
NaHZSM5 (Wang et al. 2011). The single-step technology dimethyl ether production capacity of about 20 million tons
for dimethyl ether synthesis directly from carbon dioxide of dimethyl ether per year (Methanol Institute 2020), the
and hydrogen enables to produce dimethyl ether with higher potential of CO2 utilization is about 38 million tons of car-
efficiency, by overpassing thermodynamic equilibrium lim- bon dioxide per year.
itations for CO2 conversion by in-situ dehydration of the The market size estimated for dimethyl ether by 2020 was
produced methanol, and with lower capital and operating for 8 billion Є (Fleisch et al. 2012). Therefore, assuming a
costs, because both methanol synthesis and dehydration market price of about 1600 Є/tDME, the global demand in
takes places in a single process, with no need for methanol 2020 is roughly 5 million tons of dimethyl ether. China
purification (Olah et al. 2009; An et al. 2008). consume more than 90% of the global dimethyl ether
In recent years, the production of dimethyl ether from demand and mainly for heating and cooking applications
carbon dioxide and hydrogen in a single step has advanced (Prabowo et al. 2017). The demand of dimethyl ether will
considerably toward demonstration, reaching a technical increase exponentially in the future if dimethyl ether is
readiness level of 6 (Wulf et al. 2018). A new demonstration adopted as alternative fuel for transportation and power
plant was developed and built over the past two years as part generation.
of the ALIGN-CCUS project funded by the European The demand of dimethyl ether as alternative fuel for
Commission and Member States. The demonstration plant is transportation expects to increase, especially for heavy
located at RWE’s Innovation Centre at Niederaussem power vehicles, such as trucks and ships, which cannot be easily
plant in Germany. The commissioning of the ALIGN-CCUS electrified. The demand of dimethyl ether as blended fuel for
plant started at the end of 2019. The dimethyl ether synthesis vehicles driven by liquefied petroleum gases will increase,
unit was supplied by Mitsubishi Hitachi Power Systems because infrastructures for distribution and end-use are
Europe and can produce up to 50 kg per day of dimethyl already available. One the other hand, the demand of
ether from 180 kg of CO2 and 22 kg of hydrogen using an dimethyl ether as a cleaner substitute for diesel fuel in
innovative catalyst and reactor system. CO2 will be captured transportation applications is foreseen to increase, because
from the flue gas of the coal power station in a the use of dimethyl ether will help vehicle manufacturers and
post-combustion amine scrubbing plant available on-site. end-users comply with the severer regulations (Methanol
The hydrogen will be obtained from water electrolysis in an institute 2016; Fleisch et al. 2012; Prabowo et al. 2017).
alkaline electrolyzer with a capacity of about 120 kW sup- The use of dimethyl ether as an alternative fuel to natural
plied by Asahi Kasei Europe (O’Connell et al. 2019; RWE gas for efficient power generation could play a key role in
Power 2019). the future, in special for power plants at isolated locations
The easiness of transport and storage, the clean com- where the transportation of natural gas is challenging
bustion performance, and the relatively high energy density (Methanol institute 2016; Fleisch et al. 2012; Prabowo et al.
of dimethyl ether, makes the direct conversion of recycled 2017).
CO2 and renewable H2 to dimethyl ether very attractive for
long-term chemical storage of renewable energy and as a
source of clean, renewable and climate-friendly alternative 2.4 Formic Acid
fuel.
Almost all of the dimethyl ether is currently produced by Formic acid is broadly used in the industry, not only as
catalytic dehydration of coal-derived methanol. In China, 20 insecticide, preservative, and antibacterial and reducing
million tons of dimethyl ether production capacity were agent, but also as C1 building block for the production of
expected by 2020 (Methanol Institute 2016) at a market various chemicals, as well as fuel for direct energy genera-
price close to 1600 Є/t (China Petroleum and Chemical tion in fuel cells (Álvarez et al. 2017; Panzone et al. 2020;
Industry Federation 2020). Rego de Vasconcelos and Lavoie 2019; Huang et al. 2018).
According to the analysis made by Michailos et al. Despite its relatively low hydrogen content, formic acid
(2019), the total cost associated with dimethyl ether pro- decomposes reversibly and selectively releasing hydrogen at
duction by direct hydrogenation of captured CO2 with relatively low temperature, enabling its potential application
integrated electrolysis ranges between 1828 and 2322 €/ as liquid carrier of energy and hydrogen (Álvarez et al. 2017;
tDME depending on the price of renewable electricity Panzone et al. 2020; Rego de Vasconcelos and Lavoie 2019;
(Michailos et al. 2019). Therefore, dimethyl ether produced Singh et al. 2016).
14 E. Ruiz Martínez and J. M. Sánchez Hervás

The most common process for industrial production of hydrogenation leads to lower consumption of steam and
formic acid consists of the synthesis of methyl formate from heavy fuel oil, lower water footprint and to higher electricity
carbon monoxide and methanol and subsequent hydrolysis consumption, of about 4.1 Mwh per ton of formic acid, as
of methyl formate to formic acid at high pressure and in the compared to the conventional method of formic acid pro-
presence of a huge excess of water. Formic acid can be duction (Jarvis and Samsatli 2018; Pérez-Fortes et al.
produced in greener way by direct carbon dioxide reduction, 2016a), resulting in a tenfold potential reduction in the
enabling carbon dioxide utilization and chemical storage of greenhouse gas emissions associated with formic acid pro-
renewable energy and hydrogen (Álvarez et al. 2017; Pan- duction (Gunasekar et al. 2016). Therefore, formic acid
zone et al. 2020; Pérez-Fortes et al. 2016a; Rego de Vas- production by carbon dioxide hydrogenation is advanta-
concelos and Lavoie 2019; Huang et al. 2018). geous, in terms of environmental impact, compared to its
Carbon dioxide hydrogenation to formic acid usually conventional counterpart, as long as the electricity needed
occurs over homogeneous catalysts in aqueous medium. for the carbon dioxide hydrogenation and hydrogen pro-
Catalysts based on noble metals, especially on Ru, showed duction by water electrolysis comes from a renewable source
good catalytic performance. However, the homogeneous (Jarvis and Samsatli 2018; Rego de Vasconcelos and Lavoie
catalysts are difficult to separate from the reaction products 2019). In addition to lower associated emissions of carbon
and the yield to formic acid is still low, hindering the dioxide, the process of carbon dioxide hydrogenation to
development of the process beyond a technology readiness formic acid has a net CO2 utilization of 0.7 tons of CO2 per
level of 5 (Álvarez et al. 2017; Jarvis and Samsatli 2018; ton of formic acid, resulting in a net amount of avoided CO2
Panzone et al. 2020; Pérez-Fortes et al. 2016a; Rego de emissions of 2 tons of CO2 per ton of formic acid and in a
Vasconcelos and Lavoie 2019). Homogeneous catalysts potential of CO2 utilization in the range of 4–21 million
require further enhancements in selectivity to formic acid metric tons of carbon dioxide per year only in Europe (Jarvis
and stability to become potentially applicable (Panzone et al. and Samsatli 2018; Pérez-Fortes et al. 2016a).
2020). Some companies like British Petroleum (BP) and The electrochemical reduction of carbon dioxide to for-
BASF acquired patents on the carbon dioxide hydrogenation mic acid involves the conversion of CO2, protons and
to formic acid over homogeneous catalysts (Pérez-Fortes electrons to formic acid at the cathode of an electrolytic cell.
et al. 2016a; Pérez-Fortes and Tzimas 2016). Carbon dioxide Oxygen is obtained as by-product at the anode of the elec-
hydrogenation to formic acid over immobilized homoge- trochemical system (Jarvis and Samsatli 2018). The elec-
neous catalysts or heterogeneous catalysts was recently trochemical reduction of carbon dioxide to formic acid
studied to deal with the problem of final separation of typically operates at ambient temperature and pressure, with
reaction products (Panzone et al. 2020; Rego de Vasconcelos current efficiencies up to 100% (Jarvis and Samsatli 2018).
and Lavoie 2019). The maturity of electrochemical reduction of CO2 to formic
The global production of formic acid was estimated to acid is currently limited to a technology readiness level
surpass 760 million tons of formic acid by 2019 (Jarvis and range of 5–6 (Chauvy et al. 2019; Pérez-Fortes and Tzimas
Samsatli 2018; Rego de Vasconcelos and Lavoie 2019; 2016), mainly due to the high over-potentials and low
Huang et al. 2018). The demand for formic acid is presently selectivity in formic acid formation (Rego de Vasconcelos
led by its use as chemical feedstock, but the potential and Lavoie 2019).
application of formic acid as energy and hydrogen vector Various life-cycle and techno-economic studies identified
would increase its demand in the future (Jarvis and Samsatli electro-reduction of CO2 to formic acid as a promising
2018; Singh et al. 2016). technology for further scale-up and commercialization
A techno-economic study by Pérez-Fortes et al. (2016a) (Agarwal et al. 2011; Jarvis and Samsatli 2018; Pérez-Fortes
utilizes a market price of formic acid of 650 €/t (Pérez-Fortes et al. 2016a).
et al. 2016a), in line with the current market price of formic There are some projects aiming at demonstrating the
acid around 400–620 €/t (Made in China 2020). The cost process of carbon dioxide electro-reduction to formic acid in
estimated for the production of formic acid by carbon a relevant scale and environment, especially in Europe
dioxide hydrogenation using homogeneous catalysts and (Pérez-Fortes and Tzimas 2016).
considering a plant with a production capacity of 12 kt/y and Det Norske Veritas (DNV) (2007) and Mantra Venture
a lifetime of 20 years was about 1591 €/t, corresponding to Group (Mantra 2014, 2015) are exploring the electro-
the sum of capital costs, of about 67 €/t, and operational reduction of carbon dioxide to formic acid at pilot scale
costs, of about 1524 €/t (Pérez-Fortes et al. 2016a). There- (Pérez-Fortes et al. 2016a; Pérez-Fortes and Tzimas 2016).
fore, the production of formic acid by carbon dioxide Det Norske Veritas developed the ECFORM process for
hydrogenation is not economically viable yet. the direct electro-reduction of CO2 to formic acid and for-
According also to the study by Pérez-Fortes et al. mate salts, with oxygen as by-product (Zhu 2019). DNV
(2016a), formic acid production by carbon dioxide tested the ECFORM process in a small-scale demonstration
Chemical Valorization of CO2 15

plant, of 350 kg of formic acid per year (Chauvy et al. 2019; The production of formic acid by electrochemical
Pérez-Fortes et al. 2016a; Pérez-Fortes and Tzimas 2016; reduction of carbon dioxide is environmentally beneficial
Det Norske Veritas (DNV) 2007; Robledo-Díez 2012). because of its operation at ambient temperatures and pres-
Mantra Venture Group has finished the engineering work sures resulting in a less energy and carbon intensive process.
on a pilot plant to be installed and operated at Lafarge Based on the study by Agarwal et al. (2011), a net CO2
Cement in Canada (Mantra 2014, 2015). The pilot plant can utilization of about 0.5 tons of CO2 per ton of formic acid
produce 35 tons of formic acid per year by electrochemical and an electricity requirement of about 1.1 MWh per ton of
reduction of carbon dioxide (Pérez-Fortes et al. 2016a; formic acid were assessed (Agarwal et al. 2011; Jarvis and
Pérez-Fortes and Tzimas 2016; Mantra 2014). Samsatli 2018). However, the use of renewable electricity
A new pilot plant was developed and built as part of the for the production of formic acid is decisive to avoid com-
CELBICON project funded by the European Commission. promising the mitigation capacity of carbon dioxide of the
The pilot plant includes an electrolytic cell for testing the electrochemical reduction process.
electrochemical reduction of carbon dioxide captured from
air to formic acid in a relevant environment, that is to say at a
technical readiness level of 5 (HYSYTECH 2020; Jarvis and 2.5 Ethanol
Samsatli 2018).
Recently, Twence, a waste incineration company, laun- Ethanol is commonly used as fuel additive and platform
ched the development of a pilot plant for the electrochemical chemical and, in some countries is blended, mainly with
conversion of carbon dioxide captured from flue gases into gasoline, as transportation fuel. Ethanol has a relatively high
formic acid. The pilot plant is based on an electrochemical energy density of about 7.4 kWh/kg (Handler et al. 2016).
reactor previously developed and tested in cooperation Ethanol is currently produced by direct or indirect ethylene
between Coval Energy, VoltaChem/The Netherlands Orga- hydration or biomass fermentation (Panzone et al. 2020;
nization for Applied Scientific Research (TNO), and Tech- Bordiga and Lercher 2019).
nical University of Delft (Voltachem 2019). Ethanol can be also obtained by direct hydrogenation,
The electrochemical reduction of carbon dioxide is ready electrochemical reduction or biochemical conversion of CO2
for scaling-up, but substantial technological developments (Panzone et al. 2020; Rego de Vasconcelos and Lavoie
are required before applying this process to the production of 2019). Among the different technologies currently under
formic acid at large scale. Outstanding challenges for elec- development for the production of ethanol from CO2, bio-
trochemical reduction of carbon dioxide to formic acid chemical conversion is the only one that has reached a
comprise increasing the selectivity, stability and durability degree of maturity sufficient as to consider its possible
of catalyst-electrodes and the development of less energy- commercialization (O’Connell et al. 2019).
intensive approaches to separate formic acid from the A promising process for biochemical conversion of car-
aqueous stream of products and of process in continuous for bon dioxide to ethanol at industrial level is gas fermentation.
synthesis of formic acid by carbon dioxide electro-reduction Feedstocks for gas fermentation include syngas from gasifi-
(Zhu 2019; Agarwal et al. 2011; Pérez-Fortes et al. 2016a; cation of biomass and municipal solid waste, CO-rich gas
Pérez-Fortes and Tzimas 2016; Rego de Vasconcelos and from industrial exhausts and even reformed biogas and
Lavoie 2019). mixtures of captured carbon dioxide and electrolytic hydro-
Based on a study by Agarwal et al. (2011), a net capital gen (Zhu 2019; O’Connell et al. 2019; Anggraini et al. 2018).
cost of about 94 € per ton of formic acid and a net opera- The gas fermentation process consists of reception,
tional cost of around 760 € per ton of formic acid were compression and fermentation of the syngas and separation
assessed (Agarwal et al. 2011; Jarvis and Samsatli 2018), and/or purification of ethanol. Fermentation takes place at
resulting in total production cost of 854 € per ton of formic nearly atmospheric pressure and ambient temperature,
acid, considerably higher than market price for formic acid resulting in a less energy-intensive route for ethanol pro-
indicated above, of approximately 650 € per ton of formic duction with reduced carbon footprint and operating cost
acid. Therefore, electrochemical reduction of CO2 to formic (Zhu 2019; O’Connell et al. 2019; Bordiga and Lercher
acid is not yet economically viable. 2019; Liew et al. 2016).
According also to Agarwal et al. (2011), the economic The advantages of gas fermentation in terms of efficiency,
viability of the process of electrochemical reduction of car- diversity of feedstocks and product selectivity resulted in the
bon dioxide to formic acid may increase by utilizing waste scaling-up of fermentation process for ethanol production at
water at the anode and by separating and selling by-products commercial scale (Liew et al. 2016).
of the reaction such as oxygen and hydrogen (Agarwal et al. LanzaTech is the leading company in process develop-
2011). ment for ethanol production by gas fermentation. LanzaTech
16 E. Ruiz Martínez and J. M. Sánchez Hervás

demonstrated the gas fermentation process at pilot and (RFA) 2020). The global annual demand of ethanol is pre-
pre-commercial scales. LanzaTech is currently scaling up its sently around 47.5 million tons (Renewable Fuel Associa-
process, and some commercial plants are under construction tion (RFA) 2020).
or planned (Zhu 2019; O’Connell et al. 2019; Liew et al. A techno-economic study by Medeiros et al. (2020)
2016). Accordingly, the ethanol production by gas fermen- estimated a minimum ethanol selling price of about 811 €/t
tation is a mature technology with a technology readiness for the production of ethanol via syngas fermentation to
level of 9 (O’Connell et al. 2019). become economically feasible (Medeiros et al. 2020). The
Table 4 shows pilot, pre-commercial and commercial current market price of ethanol is around 976 €/t (Global
plants based on the LanzaTech process. This table combines petrol prices 2020). Therefore, the production of ethanol by
and updates earlier reviews by Zhu (2019), O’Connell et al. fermentation of carbon dioxide-rich streams can be eco-
(2019) and Liew et al. (2016), including details such as plant nomically competitive depending on the source of syngas, as
operational status, city and country of location of the plant, the minimum ethanol selling price depends on the type of
CO2 source, plant scale and capacity, expressed in terms of gas utilized (Medeiros et al. 2020).
total ethanol production, in t/y, and installed power in kW, According to a life-cycle analysis by Ou et al. (2013),
calculated from the lower heating value of ethanol product, ethanol production by gas fermentation is advantageous in
as well as main references. terms of energy savings and reduction of greenhouse gas
The global annual production of ethanol is currently emissions compared to most bioethanol production routes
about 87 million tons (Renewable Fuel Association (Ou et al. 2013).

Table 4 Pilot, pre-commercial and commercial plants based on the LanzaTech process for ethanol production by gas fermentation
Plant Status Location Capacity t/y Scale CO2 source References
(kW) C2H5OH
LanzaTech In operation Auckland 45 (38) Pilot Steel mill off gas (Zhu 2019; O’Connell et al.
Blue Scope (NZ) 2019; Lane 2015)
LanzaTech In operation Shanghai 300 (255) Pre-commercial Steel mill off gas (Zhu 2019; O’Connell et al.
BaoSteel (CN) 2019; Liew et al. 2016; Lane
2015)
LanzaTech In operation Caofeidian 300 (255) Pre-commercial Steel mill off-gas (Zhu 2019; O’Connell et al.
Shougang (CN) 2019; Liew et al. 2016; Lane
2015)
LanzaTech In operation Kaohsiung 36 (31) Pilot Steel mill off gas (Zhu 2019; O’Connell et al.
WBT (TW) 2019; Liew et al. 2016)
LanzaTech In operation North 15 (13) Pilot Syngas MSW (Zhu 2019; Sekisui Chemical
Sekisui Japan (JP) gasification Co., LTD. and LanzaTech
2017)
LanzaTech nda Georgia 30 (26) Pilot Syngas Biomass (Zhu 2019; Lane 2015)
Freedom (US) gasification
Pines
LanzaTech In operation Caofeidian 46,000 Commercial Steel mill off-gas (Zhu 2019; O’Connell et al.
Shougang (CN) (40,900) 2019; Liew et al. 2016)
LanzaTech Under Gent (BE) 62,000 Commercial Steel mill off gas (O’Connell et al. 2019;
ArcelorMittal construction (53,600) Steleanol Project 2019)
LanzaTech Under Panipat 33,000 Commercial Refinery off-gas (Zhu 2019; O’Connell et al.
Indian Oil construction (IN) (28,100) 2019)
LanzaTech Under California 36,000 Commercial Syngas Biomass Zhu 2019; O’Connell et al.
Aemetis engineering (US) (30,600) gasification 2019)
LanzaTech Under South 57,000 Commercial Ferroalloy off-gas (Zhu 2019; O’Connell et al.
Swayana construction Africa (43,400) and Titania 2019)
(ZA) smelter
This table compiles pilot, pre-commercial and commercial plants based on the LanzaTech process for ethanol production by CO2-containing gas
fermentation worldwide. This table includes details about plant operational status, city and country of location of the plant, CO2 source, plant scale
and capacity, which give an idea of the level of development, deployment and sustainability of ethanol production by gas fermentation around the
world.
NZ New Zealand, CH Switzerland, TW Taiwan, JP Japan, MSW Municipal Solid Waste, nda no data available, US United States of America, BE
Belgium, IN India, ZA South Africa
Chemical Valorization of CO2 17

The production of ethanol via gas fermentation has a net commercially available technology with a technology
CO2 utilization of 1.9 tons of CO2 per ton of ethanol, readiness level of 9 (O’Connell et al. 2019). The
resulting in a potential of CO2 uptake of about 165 million Power-to-Liquids technology, via syngas production by
tons of carbon dioxide per year worldwide (Chauvy et al. reverse water gas shift and subsequent Fischer–Tropsch
2019; Handler et al. 2016). synthesis, is almost ready for commercialization with a
technology readiness level between 8 and 9 (O’Connell et al.
2019; Schmidt et al. 2016).
2.6 CO2-Fischer–Tropsch Liquid Fuels Integration of the individual processes involved in
Power-to-Liquids technology at large scale is still under
Liquid fuels, such as diesel, gasoline, and jet fuel or kero- development (Schmidt et al. 2016). By the time being, a
sene, are extensively utilized for transport. Much of the CO2 small number of Power-to-Liquids plants are currently
emitted into the atmosphere results from the combustion of operational and some demonstration projects are in progress,
fossil fuels in vehicles, making necessary the development especially in Europe, driven by the need to decrease green-
of methods, such as the Power-to-Liquids technology, for house gas emissions and increase the share of renewable
the production of liquid transportation fuels from CO2, water energy. There are also some plants announced and planned
and renewable electricity. Power-to-Liquids technology in Switzerland, Norway and Canada (Zhu 2019; O’Connell
enables to decrease the greenhouse gas emissions associated et al. 2019; Panzone et al. 2020; Rego de Vasconcelos and
with the transportation sector while obtaining an economic Lavoie 2019; Wulf et al. 2018).
benefit and storing renewable energy (O’Connell et al. 2019; A non-exhaustive list of Power-to-Liquids plants or
Schmidt et al. 2016). projects for the production of gasoline, diesel and kerosene
Fuels derived from carbon dioxide take on special is provided in Table 5 (Zhu 2019; O’Connell et al. 2019;
importance in the aviation sector, where the use of other Panzone et al. 2020; Rego de Vasconcelos and Lavoie 2019;
low-carbon energy carriers, such as electricity or hydrogen, Wulf et al. 2018). This table combines and updates earlier
is particularly challenging (International Energy Agency reviews by Zhu (2019), O’Connell et al. (2019), Panzone
(IEA) 2019). et al. (2020), Rego de Vasconcelos and Lavoie (2019) and
There are two main ways for the production of gasoline, Wulf et al. (2018), including details such as CO2 conversion
diesel and jet fuel or kerosene via Power-to-Liquids tech- route, plant operational status, city and country of location of
nology: methanol synthesis and conversion and Fischer– the plant, target product, CO2 source, plant capacity,
Tropsch synthesis and subsequent upgrading. Both Fischer– expressed in terms of total syncrude production, in t/y, and
Tropsch and methanol pathway consist of three steps: installed power in kW, calculated from the average lower
hydrogen production by water electrolysis powered by heating value of syncrude, as well as main references.
renewable electricity, carbon dioxide conversion to the According to the Power-to-Liquids plants currently in
intermediate product, carbon monoxide or methanol, and operation in Europe (see Table 5), the installed production
synthesis of liquid hydrocarbons and subsequent upgrading capacity of renewable transportation fuels is still low, nearly
or conversion to the target fuel, respectively (O’Connell 160 tons of syncrude per year or about 200 KWh, consid-
et al. 2019; Panzone et al. 2020; Schmidt et al. 2016). ering a low heating value of 11.94 kWh/kg for the syncrude.
In case of the Fischer–Tropsch route, CO2 is firstly For some plants, the capacity is unknown. In addition, there
converted to CO, by reverse water gas shift reaction or by are many commercial-scale plants announced or planned.
co-electrolysis of CO2 and water, and then, to long-chain Therefore, the production capacity of renewable fuels can
hydrocarbons by the Fischer–Tropsch reaction in the pres- considerably increase in the short term.
ence of cobalt or iron catalyst (Jarvis and Samsatli 2018). Renewable transportation fuels with almost zero net
The obtained synthetic crude requires subsequent conven- greenhouse gas emissions are essential in reducing green-
tional upgrading processes, by hydrocracking, isomerization house gas emissions in order to meet the Paris agreement
and distillation, to gasoline, diesel or kerosene (Schmidt (Schmidt et al. 2016). The final demand of renewable fuels
et al. 2016). In case of the methanol route, methanol is for road vehicles, locomotive, aviation and navigation will
converted to gasoline, diesel and kerosene by a series of strongly depend on the level of electrification of the trans-
reactions including dimethyl ether synthesis, olefin synthe- portation sector (O’Connell et al. 2019). According to a
sis, oligomerization and hydrotreating (O’Connell et al. study by O’Connell et al. (2019), even for highly electrified
2019; Panzone et al. 2020; Schmidt et al. 2016; Rego de vehicle scenarios, roughly 347 GW or, based on low heating
Vasconcelos and Lavoie 2019). value of syncrude and assuming a full load period of the
Both Power-to-Liquids routes, via Fischer–Tropsch or Power-to-Liquids plant of 4000 h/year, 116 thousands of
methanol, has a high level of technology readiness. The tons per year of Power-to-Liquids have to be installed in the
methanol-to-liquid fuel process is a mature and European Union by 2050.
18 E. Ruiz Martínez and J. M. Sánchez Hervás

Table 5 Plants or projects for Power-to-Liquids


Plant/project Route Status Location Capacity t/y Target Product CO2 References
(kW) Fuel source
Sunfire PtL RWGS/coSOEC-FT In Dresden (DE) * 46 Diesel Air (Zhu 2019; O’Connell
operation (*63) captured et al. 2019; Panzone
CO2 et al. 2020; Rego de
Vasconcelos and
Lavoie 2019)
Audi PtL RWGS-FT Announced Laufenburg * 320 Diesel Biomass (O’Connell et al. 2019;
(CH) (*435) plant Höpfner 2017)
GreenPower2Jet RWGS-FT Announced Stade/Lingen 10,000 Kerosene Air (O’Connell et al. 2019;
(DE) (*14,000) captured Bio-based News 2019;
CO2 Neuling and
Kaltschmitt 2019)
KEROSyN100 methanol Announced Heide (DE) nda Kerosene Waste (O’Connell et al. 2019)
CO2
from
refinery
Nordic Blue coSOEC-FT Planned Herøya (NO) 8,000 Diesel Air (Zhu 2019; O’Connell
Crude (*10,000) captured et al. 2019; Panzone
CO2 et al. 2020; Sherrard
2017)
Powerfuel RWGS-FT In Karlsruhe * 90 Kerosene Air (O’Connell et al. 2019;
operation (DE) (*120) captured Zitscher et al. 2019)
CO2
SOLETAIR RWGS-FT In Lappeenranta 21 (*30) Gasoline Air (O’Connell et al. 2019;
operation (FI) captured Panzone et al. 2020;
CO2 Soletair 2020)
Sundance Clean Methanol Announced British 693,500 Gasoline + diesel Flue gas (O’Connell et al. 2019;
Methanol/Blue Columbia, (*950,000) Blue Fuel Energy
fuel Energy (CA) 2020)
Carbon RWGS + FT Planned nda * 80,000 Syncrude Air (Zhu 2019; Rego de
Engineering— (*100,000) captured Vasconcelos and
Air to fuel CO2 Lavoie 2019; Design
system Engineering 2019)
This table compiles Power-to-Liquids plants or demonstration projects for the production of gasoline, diesel and kerosene currently in operation,
announced or planned mainly in Europe, as reported in literature. This table includes details about plant operational status, city and country of
location of the plant, target product, CO2 conversion route, CO2 source and plant capacity, which give an idea of the level of development,
deployment and sustainability of Power-to-Liquids technology and the potential for producing alternative gasoline, diesel or kerosene
transportation fuels from carbon dioxide mostly at European level
RWGS Reverse Water Gas Shift, coSOEC Co-electrolysis of water and CO2 in Solid Oxide Electrolyte Cells, FT Fischer–Tropsch, DE Germany,
CH Switzerland, nda no data available, NO Norway, FI Finland, CA Canada

The estimated net CO2 utilization of the Power-to-Liquids dioxide is captured directly from air or from renewable
process via the Fischer–Tropsch route is about 2.6 t CO2/t sources (Jarvis and Samsatli 2018; Panzone et al. 2020).
liquid fuel (Jarvis and Samsatli 2018). Therefore, consider- The production of fuels through the Fischer–Tropsch
ing a production capacity of Power-to-Liquids of about 116 route has the lowest water demand, land requirements and
thousands of tons per year, only in Europe, the potential of greenhouse gas emissions and the highest energy efficiency,
CO2 utilization would be about 302 thousands of tons of as compared to other production technologies, such as bio-
carbon dioxide per year by 2050. fuels, biomass-to-liquid, carbon-to-liquid and gas-to-liquid
The energy consumption of the Power-to-Liquids process (Panzone et al. 2020; Schmidt et al. 2016).
via the Fischer-Tropsch route is about 6.8 kWh per ton of Different techno-economic studies estimated a production
liquid fuel produced (Jarvis and Samsatli 2018).Therefore, cost for liquid fuels synthetized via the Fischer–Tropsch
the Power-to-Liquids process has neutral or negative carbon route ranging between about 536 and 1992 € per ton of
balance only if the energy required for the production of the liquid fuel depending mainly on the type of electrolysis
liquid fuel comes from renewable sources and if carbon process and carbon dioxide source utilized, while the
Chemical Valorization of CO2 19

production cost of the same liquid fuels from fossil sources zirconium, magnesium, copper, zinc, chromium, vanadium
ranges between roughly 272 and 320 € per ton of liquid fuel, and lanthanum, or a combination of them (Schaaf et al.
depending on the type of fuel (Panzone et al. 2020). 2014; Kondratenko et al. 2013; Centi et al. 2013; Saeidi
Therefore, transportation fuels produced via Power-to- et al. 2014; Wang et al. 2011; Rodemerck et al. 2013).
Liquids are not yet cost-competitive as substitute for con- Some reactor configurations, such as fluidized bed and
ventional fossil fuels. slurry reactors, facilitate the removal of the heat generated
CO2 can be also converted directly into liquid fuels, such by the carbon dioxide hydrogenation, leading to improved
as gasoline (Schmidt et al. 2016; Wei et al. 2018, 2017; Choi conversion of carbon dioxide to hydrocarbons. Other reac-
et al. 2017; Liu et al. 2019) via the CO2 hydrogenation tion configurations, such as serial or recirculating reactors,
reaction over iron based catalysts. However, the product allow for increased residence time, and thus higher pro-
distribution can be wide depending on the structure and duction of hydrocarbons in the reactor (Saeidi et al. 2014).
composition of the catalysts. Hydrocarbons products mainly Another way to improve the conversion of carbon dioxide to
consisted in low molecular weight hydrocarbons, such as hydrocarbons is by removing in situ water using a
paraffins and olefins, instead of heavier products with higher perm-selective silica membrane integrated into a membrane
added value as liquid transportation fuels. Different types of catalytic reactor (Centi et al. 2013).
co-catalysts, such as copper and cobalt, promoters, such as
potassium, and metal oxide supports, such as alumina, silica,
titania and zeolites, are employed to tune the product dis- 2.7 Carbon Monoxide—Syngas
tribution toward heavier hydrocarbons (Choi et al. 2017).
According to literature, the combination of iron, potassium Both syngas, a mixture of carbon monoxide and hydrogen,
and zeolites, makes the catalyst highly active and selective and pure carbon monoxide are crucial building blocks for
for CO2 hydrogenation to long-chain hydrocarbons (Ye et al. industrial production of several fuels and chemicals (Keim
2019). 1989). Syngas is conventionally produced from fossil sour-
The CO2 hydrogenation to liquid fuels is considered as a ces by partial oxidation of hydrocarbons or coal or by cat-
modification of the traditional Fischer–Tropsch process, alytic steam reforming of natural gas. Pure CO is obtained
which uses syngas, a mixture of CO and H2, to produce from syngas by gas separation (Jarvis and Samsatli 2018;
liquid fuels (Panzone et al. 2020). However, the use of a Lavoie 2014).
single reactor for direct CO2 hydrogenation is advantageous Given that syngas is a feedstock for conventional pro-
compared to the classical Fischer–Tropsch route due to its duction of methanol and higher hydrocarbons by mature
ease of operation and lower CO2 conversion cost (Ye et al. synthesis technologies (Behrens et al. 2019; Prieto 2017),
2019). the development of technologies for carbon dioxide con-
One of the main challenges for advancing CO2 hydro- version to syngas represents a more climate-friendly route
genation to liquid fuels is increasing the energy efficiency for sustainable production of fuels and chemicals.
and reducing the investment and operating costs of the One method to produce syngas from carbon dioxide and
process and the integration of renewable energy sources in methane is the catalytic dry reforming of methane. Dry
the process (Whipple and Kenis 2010). The tendency is to reforming of methane has many environmental, technical
maximize the yield to desired product with a minimum and economic advantages compared to conventional tech-
renewable energy input. However, the synthesis of hydro- nologies for syngas production. The dry reforming process
carbons from CO2 over conventional heterogeneous cata- operates at milder temperatures and pressures than steam and
lysts is favored at high pressures (high compression power) autothermal reforming processes (Mondal et al. 2016) and
and low temperatures (exothermic) and are slow processes, uses recycled carbon dioxide instead of water for reforming,
which implies the use of high residence times (high reactor avoiding energy consumption associated with steam gener-
volume) or feed recycling ratios (high power consumption) ation and decreasing the carbon footprint associated with the
to obtain significant conversions. In addition, it is necessary syngas production (Jarvis and Samsatli 2018; Er-rbib et al.
to improve activity, selectivity and stability of the catalyst 2012; Schwab et al. 2015).
and to minimize carbon deposition and undesirable methane Dry reforming of methane produces a syngas with a
formation. hydrogen to carbon monoxide ratio more compatible with
Different processes have been developed in fixed bed some downstream synthesis processes such as Fischer–
reactors operating at high pressure, between 10 and 40 bar, Tropsch synthesis (Jarvis and Samsatli 2018; Lavoie 2014;
and low temperature, between 200 and 350 °C, using cata- Schwab et al. 2015). According to a study by Mondal et al.
lysts based on iron over different supports, such as alumina, (2016), the cost associated with methanol synthesis from dry
silica, titania and zeolite, or a combination of them, and reforming of methane is lower than the equivalent cost of
improved with promoters, such as potassium, rubidium, methanol production from steam reforming of methane
20 E. Ruiz Martínez and J. M. Sánchez Hervás

(Jarvis and Samsatli 2018; Mondal et al. 2016). Dry electrolysis cells or at low temperature in gas diffusion or
reforming is also a more cost-effective alternative to partial solution-phase electrolysis cell (Qiao et al. 2014).
oxidation for syngas production in plants with medium and Haldor Topsoe has developed and commercialized a
small size (Schwab et al. 2015). modular technology called eCOs™ for onsite production of
The industrial application of dry reforming of methane pure carbon monoxide from carbon dioxide via solid oxide
for valorization of carbon dioxide is still limited (Er-rbib electrolysis, with plant capacities up to a few hundred of
et al. 2012), having a technology readiness level of up to 6. normal cubic meter of carbon monoxide per hour (Zhu 2019;
The Linde Group built a dry reforming pilot plant at Pullach Andersen 2017; Haldor-Topsoe 2020). The first commercial
in Germany (The Linde Group 2015). Nowadays, after system, having a capacity of 12 Nm3/h, commenced oper-
completion of the testing at pilot scale, the Linde Group is ating in 2016 at Gas Innovations in Texas (Mittal et al.
aiming at upscaling the catalyst on the way for commercial 2017).
application (The Linde Group 2020). Major challenges for increasing the deployment of solid
Catalysts utilized in carbon dioxide reforming of methane oxide electrolysis of carbon dioxide include improving the
comprise nickel, noble metals, cobalt and metal carbides in stability of the electrodes and the ionic conductivity of the
fixed bed reactors (Lavoie 2014). The main technological electrolytes, and enhancing the tolerance to impurities (Qiao
challenge for dry reforming of methane is the readiness of et al. 2014).
cheap and widely available catalysts resistant to deactivation The electrolysis of carbon dioxide at low temperature is
by coking and with high selectivity to syngas (Jarvis and still under development.
Samsatli 2018; Behrens et al. 2019; Kim 2017). Siemens tested carbon dioxide electrolysis on larger-scale
Other way to obtain carbon monoxide from carbon gas diffusion electrodes, of 10 and 100 cm2, in flow cell
dioxide is the reverse water gas shift reaction. In the reverse configurations (Jeanty et al. 2018). Next, Siemens collabo-
water gas shift reaction, carbon dioxide reacts with renew- rated with Evonik in the development of a hybrid system for
able hydrogen to form carbon monoxide and water, but the production of chemicals by connecting their small
subsequent removal of water is needed before the down- electrolyzer with a fermentation process (Haas et al. 2018).
stream Fischer–Tropsch or methanol synthesis in order to Dioxide Materials explored the electrolysis of carbon
avoid catalyst inhibition and equilibrium limitation by water, dioxide and the co-electrolysis of water and carbon dioxide
enabling milder operating conditions for the synthesis pro- in an anion-conductive membrane-based electrolyzer,
cess (Behrens et al. 2019; Wang et al. 2011). The reverse resulting in the production of carbon monoxide and syngas,
water gas shift reaction is not currently available at industrial respectively at realistic rates (Kutz et al. 2017; Liu, et al.
scale (Behrens et al. 2019), being at a technical readiness 2016). Remaining challenges for the low-temperature elec-
level of about 6 (Jarvis and Samsatli 2018; Schmidt et al. trolysis of carbon dioxide to become feasible include
2016). The technical viability of the CAMERE process improving stability and durability of electrodes, minimizing
concept, consisting of three consecutive steps: reverse water loss of carbon dioxide to the liquid electrolyte and reducing
gas shift reaction, water removal and conventional methanol overall energy requirement under operating conditions at
synthesis, was demonstrated, but additional research and practical production rates of carbon monoxide (Liu et al.
development is needed for commercial application of the 2016).
process, due to a lack of economic feasibility (Joo et al.
1999).
Strategies to increase the yield of carbon monoxide via 3 CO2 Chemically Derived Materials
the reverse water gas shift reaction include removing prod-
ucts, mainly water, in situ from the reaction medium and CO2 can also be chemically utilized for the production of
using high temperatures, given the endothermicity of the materials with different applications.
reaction. The main challenge in the development of catalyst
for reverse water gas shift reaction is the improvement of
stability and selectivity of the catalyst at high temperature in 3.1 Polymers
order to avoid hydrothermal deactivation of the catalyst and
undesirable methane formation, respectively (Behrens et al. Polymers, such as polyurethanes and polycarbonates, are
2019; Wang et al. 2011). used in the manufacturing of plastics, resins and foams,
Other method for carbon monoxide production from which have a wide range of applications, such as in build-
carbon dioxide is the electrolysis of carbon dioxide directly ings and cars (International Energy Agency (IEA) 2019; Qin
to carbon monoxide and oxygen. Electrolysis of carbon et al. 2015). Petroleum is the traditional feedstock for the
dioxide operates either at high temperature in solid oxide production of polymers. The carbon dioxide can partially
Chemical Valorization of CO2 21

replace petrochemicals as raw material for the synthesis of Technologies 2018). Econic Technologies has released a
polymers, such as in the copolymerization of epoxides with plant for demonstrating the full polycarbonates production
carbon dioxide for the production of polycarbonates (Zhu process from copolymerization reactor to the product treat-
2019; Chauvy et al. 2019; International Energy Agency ment system (Econic Technologies 2018).
(IEA) 2019; Ampelli et al. 2015). Covestro developed a plant in Dormagen, Germany, for
Replacing petrochemical feedstocks with CO2 in polymer the copolymerization of propylene oxide with carbon diox-
production is potentially beneficial from an economic and ide to produce 5000 t/y of polyether-polycarbonate polyols
environmental point of view, owing to the relatively low suitable for polyurethane foam applications, without unde-
energy requirements and reduced impact on climate change sirable by-products formation. The polymer, branded as
associated with processing polymers with CO2, and enables cardyon®, contains up to 20 Wt.% of carbon dioxide sourced
the production of biodegradable polymers with innovative from waste gases of a nearby ammonia production plant
features (Zhu 2019; Chauvy et al. 2019; International Energy (Zhu 2019; Chauvy et al. 2019; Covestro 2020; Fernán-
Agency (IEA) 2019; Ampelli et al. 2015; Alberici 2017; dez-Dacosta, et al. 2017; Langanke et al. 2015).
Assen 2015). Novomer Inc. developed a process for the copolymer-
Polycarbonates are classically synthesized by reaction of ization of carbon dioxide and propylene oxide to
1,2-diols with phosgene. Phosgene is toxic and corrosive. polypropylene carbonate polyols, branded as Converge®.
An alternative route for the selective synthesis of polycar- A commercial-scale facility in Texas, USA, annually pro-
bonates is the copolymerization of epoxides, such as ethy- duces several thousands of Converge® polyols incorporating
lene oxide, propylene oxide, cyclohexene oxide, vinyl oxide up to 50 wt.% of carbon dioxide. The Converge® polyols are
and styrene oxide, and CO2 over homogeneous or hetero- applicable to the formulation of polyurethane-based sealants,
geneous catalysts based on transition metals (Qin et al. 2015; coatings, adhesives and foams with improved performance,
Lu and Darensbourg 2012; Poland and Darensbourg 2017). weatherability and strength and with lower content of
In addition, according to Fukuoka et al. (2007), the carbon petrochemical feedstock and polyols production cost (Zhu
dioxide copolymerization process has lower expenditure cost 2019; Korosec 2016; Novomer 2020).
as compared to conventional process using phosgene (Zhu There are also some producers of polymers based on
2019; Fukuoka et al. 2007). carbon dioxide in China. In 2015, Nanyang Zhongju Tian-
There are many companies and institutions developing guan Low-Carbon Technology Company started to produce
and producing polymers based on carbon dioxide. 25,000 t/y of biodegradable polypropylene carbonate by
The Asahi Kasei Corporation commercialized the first copolymerization of propylene oxide, derived from its
process for producing phosgene-free polycarbonate from ethanol production process, and carbon dioxide and was
ethylene oxide and carbon dioxide with high selectivity and constructing a new copolymerization plant with a production
yield to polycarbonates, avoiding the need for separation and capacity of 100,000 t/y. Jinlong Green Chemical Company
purification of the reaction products and the treatment or manufactures aliphatic polycarbonate polyols and
disposal of residues (Zhu 2019; Chauvy et al. 2019; Inter- biodegradable polyurethane foam based on carbon dioxide.
national Energy Agency (IEA) 2019; Fukuoka et al. 2007). Inner Mongolia Mengxi High-Tech Group Company fabri-
Based on the Asahi Kasei copolymerization process, a cates 3000 t/y aliphatic polycarbonate by copolymerization
commercial facility in China produces about 150,000 tons of of waste carbon dioxide from an own cement kiln (Zhu
polycarbonates per year from carbon dioxide (International 2019). Jinioong-Cas Chemail Co. produces polyols with a
Energy Agency (IEA) 2019; Fukuoka et al. 2007). Asahi capacity of 10 kt/y (Aresta et al. 2014). Sinopec SABIC
Kasei Corporation licensed its technology to various com- Tianjin Petrochemical Co. is currently building a plant in
panies, leading to the construction of several plants in South Tianjin for the production of 260,000 t/y polycarbonate. The
Korea, Russia and Saudi Arabia with a total polycarbonate plant will be in operation by 2020 (Aresta et al. 2014;
production capacity of 1.07 Mt/y by 2019, enabling the Volkova 2019).
incorporation of 0.185 MtCO2/y into the polycarbonates Newlight Technologies in USA developed a biocatalytic
produced (Zhu 2019). process to produce a biodegradable thermo-polymer, trade-
Empower Materials currently sells polyethylene carbon- marked as AirCarbon, from captured CH4 or CO2 emissions.
ate made from ethylene oxide and carbon dioxide (Quadrelli AirCarbon is claimed as a carbon-negative material cheaper
et al. 2011). than its oil-derived equivalents. Commercial production of
Econic Technologies in UK developed a catalytic process AirCarbon started in 2013, and Newlight signed several
for the production of polycarbonate polyols without signif- Production License Agreements with different companies to
icant by-product formation and using up to 50 percent by sell several thousand tons of AirCarbon polymer by year
weight of carbon dioxide captured in a coal-fired power from different manufacturing plants (Newlight Technologies
plant (Quadrelli et al. 2011; Broadwith 2015; Econic 2020).
22 E. Ruiz Martínez and J. M. Sánchez Hervás

The synthesis of polycarbonates by copolymerization of Alternative Ca or Mg sources for CO2 carbonation


epoxides and CO2 is currently ready for industrial applica- include a variety of alkaline industrial residues from power
tion at large scale (Zhu 2019) with a technology readiness plants or industrial processes, leading to further economic
level of 8–9 (Chauvy et al. 2019). However, despite the and environmental benefits, as the carbonation process
relative maturity of this technology, there are still opportu- converts both solid wastes and captured CO2 into marketable
nities for progressing. The carbon dioxide content in poly- products and enables the permanent storage of carbon
carbonates is currently limited to a maximum of 50% CO2 dioxide and the stabilization of the toxic compounds con-
by weight. Therefore, the copolymerization process needs tained in wastes within the carbonated products (Zhu 2019;
further research and development to increase the incorpo- Aresta et al. 2014).
ration of CO2 into the copolymers (International Energy The curing of concrete with CO2 is a mature and
Agency (IEA) 2019; Quadrelli et al. 2011; Alberici 2017; encouraging technology for the utilization of CO2, while the
Assen 2015). In some processes, the scale of production of incorporation of CO2 in the manufacture of the cement itself
polyether carbonates derived from CO2 is too small to is at a lower level of development (International Energy
replace existing conventional polyol plants. Therefore, the Agency (IEA) 2019).
carbon dioxide polymerization technology requires further A crucial challenge for the deployment of CO2 carbona-
development to produce polyols on a larger scale (Chauvy tion at large scale is to speed up the carbonation reaction by
et al. 2019). increasing temperature and pressure of the process and by
Current research on copolymerization of CO2 focuses on pre-treatment of the mineral or solid waste using mechanical
the development of catalyst for producing polymers with and chemical methods (Zhu 2019; Aresta et al. 2014).
tailor-made features and from renewable epoxides, such as
limonene oxide, cyclohexadiene oxide and a-pinene oxide (a) Cement-Concrete
(Poland and Darensbourg 2017).
The estimated production and demand for polycarbonates The curing of concrete with CO2 entails converting CO2,
worldwide were approximately 5–6 Mt/y and 4–5 Mt/y, calcium silicate in cement and water into hydrated calcium
respectively for 2016. The market price of polycarbonates silicate and calcium carbonate via carbonation during the
varied between 3120 and 3830 Є per ton during the last few mixing of concrete (International Energy Agency
years, and it probably will decrease in the future as the (IEA) 2019). As carbonation is exothermal, the heat released
production process moves from the conventional method to during the reaction accelerates the curing process, decreasing
the copolymerization of carbon dioxide (Aresta et al. 2014). the consumption of fossil fuels or steam for heating and
Regarding the climate benefits of the synthesis of poly- resulting in energy savings and emission reduction (Zhu
carbonates from carbon dioxide copolymerization in com- 2019; Aresta et al. 2014).
parison with the conventional methods based on phosgene, CarbonCure Technologies and Solidia Technologies are
the estimated net CO2 utilization for the copolymerization leading the development and commercialization of the
process is about 0.173 tons of CO2 per ton of polycarbonate technology for curing concrete with CO2 (Zhu 2019; Inter-
(Chauvy et al. 2019). Therefore, considering a global national Energy Agency (IEA) 2019; CarbonCure 2020;
installed capacity of 5 million tons of polycarbonates per Solidia 2020).
year (Aresta et al. 2014), the potential of CO2 uptake is The CarbonCure process for concrete curing with CO2
about 1 million tons of carbon dioxide per year. shows a series of advantages versus conventional methods,
such as operation under atmospheric pressure, simplifying
the design of the curing chambers and using shorter curing
3.2 CO2-Derived Building Materials times, resulting in cost savings, while obtaining a concrete
with the same or improved quality. However, the use of
CO2 can be used in the production of building materials to liquid CO2 penalizes the economy of the curing process. The
partially replace water as curing agent in concrete manu- net CO2 emission avoided by the CarbonCure process is
facturing or as a raw material in the fabrication of concrete about 18 tons of carbon dioxide per cubic meter of concrete,
constituents, such as cement and construction aggregates as a result of the reduced use of cement and the incorpora-
(International Energy Agency (IEA) 2019). Building mate- tion of carbon dioxide in the concrete in comparison with
rials can be obtained from CO2 via carbonation processes, concrete produced by traditional methods (Zhu 2019;
involving the reaction of a calcium or magnesium source Monkman and MacDonald 2017; Monkman et al. 2016).
with carbon dioxide in the presence of water to produce The CarbonCure process is easily integrated into con-
carbonates suitable for concrete applications (International ventional systems for concrete production without disturbing
Energy Agency (IEA) 2019). normal operation of the plants. The CarbonCure process is
Chemical Valorization of CO2 23

currently implemented in many facilities for ready-mix kiln dust, municipal waste incineration ash, air pollution
concrete production, mostly in North America, and the ret- control wastes, mining residues, fly ashes and asbestos,
rofit of more plants is planned. The application of the Car- coming from power generation and other industrial sectors,
bonCure technology for the conversion of CO2 waste from such as steel making, cement, paper and mining industries,
cement industry into concrete suitable for use in construction otherwise stored in landfills (International Energy Agency
was first demonstrated in 2018 in USA (Zhu 2019; Chauvy (IEA) 2019; Quadrelli et al. 2011; Carbon8 2020).
et al. 2019; Sanna et al. 2014). Different companies are scaling up the technology of
Solidia Technologies in USA commercializes processes waste carbonation leading to the consumption of about 75
for the manufacture of cement and concrete using CO2 (Zhu kilotons of carbon dioxide per year (International Energy
2019). The Solidia technology promises to simplify and Agency (IEA) 2019).
reduce the costs and the water and carbon dioxide footprints The British company Carbon8 Systems developed and
of the carbonation process compared to traditional methods commercialized a technology to produce an aggregate from
of production, while obtaining cement and concrete with captured CO2 and wastes (Zhu 2019; Chauvy et al. 2019;
improved performance. As an example, the Solidia concrete Patricio et al. 2017; Sanna et al. 2014). The Carbon8 process
requires 24 h to reach complete strength compared to the up stored more carbon dioxide within the aggregate than the
to 28 days needed for the curing of the concrete produced by CO2 emitted during the carbonation process, leading to a
classical methods. In addition, the Solidia process for curing carbon-negative balance for the process (Carbon8 2020). In
concrete is easy to implement in existing manufacturing addition, the Carbon8 process resulted in lower water and
facilities and is adjustable to different production methods, energy consumption, as uses rainwater for manufacturing of
concrete formulations and standards. The maximum capacity the aggregate and electricity only to transport the materials
of CO2 uptake of the Solidia process is about 0.3 tons of through the plant, without producing any waste by-product
CO2 per ton of cement used to make the concrete (Zhu 2019; Carbon Upcycling 2020).
(DeCristofaro and Opfermann 2015). The first commercial plant based on carbon8 technology
Solidia and CarbonCure reported a reduction in carbon is currently producing about 65,000 t/y of lightweight
footprint of concrete about 70 and 80%, respectively (Car- aggregate using wastes from the air pollution control of an
bonCure 2020; DeCristofaro and Opfermann 2015). incineration facility. Another plant for the production of
The market of concrete was about 32,000 Mt/y by 2014 100,000 t/y was commissioned in 2016, and three additional
and was foreseen to increase at an annual rate of 0.8–1.2%/y plants with the same production capacity or higher would
until 2030 (Aresta et al. 2014). Therefore, the CO2 mitiga- likely to be operational in 2018 (Zhu 2019; Carbon8 2020;
tion potential of the production of building materials by Carbon Upcycling 2020).
carbon dioxide carbonation is substantial (Zhu 2019). Skyonic developed the SkyMine process (Carbonfree
In summary, concrete cured with CO2 may have superior Chemicals 2020) for the capture and carbonation of carbon
performance, reduced manufacturing costs and lower water dioxide to produce, among others, construction aggregates,
and CO2 footprints as compared with concrete produced by while also removing heavy metals and nitrogen and sulfur
conventional methods (International Energy Agency oxides from exhaust gases of industrial and power plants
(IEA) 2019). However, compliance with existing quality (Zhu 2019; Chauvy et al. 2019; Quadrelli et al. 2011). The
standards and regulations may delay the deployment of SkyMine technology was first integrated at Capitol
carbon dioxide curing of concrete to the manufacture of Aggregates cement plant in Texas, USA, in 2015. The
ready-mixed and precast concrete until long-term trials plant can save about 83,000 tons of CO2 by year (Zhu
demonstrate its environmental friendly performance (Inter- 2019; Chauvy et al. 2019; Sanna et al. 2014; Carbonfree
national Energy Agency (IEA) 2019). Meanwhile, Chemicals 2020).
non-structural uses of concrete, such as in the construction of Mineral Carbonation International (MCi) developed a
floors, ditches and roads, represent the target for early technology for waste carbonation by combining CO2 from
application of concrete cured with CO2 (International industrial sources, such as flue gases of power generation,
Energy Agency (IEA) 2019). cement and steel industries, with low-rank minerals or
wastes to manufacture of building products. MCI built a
(b) Aggregates pilot plant for scaling up and testing of the waste carbonation
technology in New South Wales, Australia, and is currently
Construction aggregates, small particles utilized in the fab- moving ahead toward first industrial demonstration plants
rication of building materials, can be obtained via reaction of for processing about 20,000 tons of carbon dioxide per year
carbon dioxide with wastes rich in magnesium or calcium, (Chauvy et al. 2019; Mineral Carbonation International
such as steel and blast furnace slags, bauxite waste, cement (MCi) 2020).
24 E. Ruiz Martínez and J. M. Sánchez Hervás

In summary, the manufacturing of construction aggre- target product, being direct or indirect carbon dioxide
gates from wastes and carbon dioxide enables reduction of hydrogenation for methanol, methane and dimethyl ether or
carbon dioxide emissions and disposal of industrial wastes Fischer–Tropsch synthesis, respectively and gas fermenta-
while potentially producing marketable products. The CO2 tion, electrochemical reduction and solid oxide electrolysis
mineralization technologies have the potential to take for ethanol, formic acid and carbon monoxide/syngas pro-
advantage of the high volumes of CO2 emissions common in duction, respectively. However, there are still some key
the cement industry, leading to a huge potential of CO2 barriers for further development and commercialization of
mitigation. However, the overall environmental and climate the chemical valorization technologies and products.
benefits associated with the manufacturing of construction In the case of catalytic alternatives to react CO2, or
aggregates from wastes and CO2 depend on the energy derived CO, and H2 for the synthesis of carbon based
requirements of the specific production process. products, the current technological challenges are increasing
The use of CO2 for manufacturing of building materials energy efficiency while reducing the cost of the conversion
offers products with superior performance and lower cost as process.
compared with conventional methods of production of Clearly, the development of novel catalysts/electrocatalyst/
building materials (Zhu 2019; International Energy Agency biocatalysts and process designs are needed to accelerate
(IEA) 2019). widespread penetration of greener processes for CO2 con-
Materials of construction based on CO2 and wastes can be version to fuels and chemicals by improving catalyst effi-
competitive versus commercial cement and aggregates as ciency, selectivity, stability and durability under long-term,
they offset the costs associated with conventional waste intermittent and unsteady operation, by optimizing catalyst-
disposal. However, in terms of market penetration, tech- reactor designs for better thermal control, renewable energy
nologies of waste carbonation are held back by the low costs integration and product separation, to surpass equilibrium
of alternative raw materials, such as limestone, adherence to limitations and to avoid catalyst deactivation, as well as to
quality standards in the building sector and compliance with develop technologically and economically viable processes
end of waste regulations. In addition, the cement industry is for the conversion of CO2 into fuels and chemicals on a
very conservative, and new construction materials are diffi- commercial scale. Another bottleneck for the market com-
cult to bring to market unless long-term trials demonstrate petitiveness of CO2-based fuels and chemicals is the cheap
their safe and environmental friendly performance (Chauvy production of carbon-free hydrogen and the availability of
et al. 2019; International Energy Agency (IEA) 2019; low-cost renewable electricity and feedstock CO2.
Quadrelli et al. 2011). CO2-derived fuels and chemical can provide greenhouse
gas emission savings, but the utilization of low-carbon
energy and hydrogen for their production is critical. In
4 Conclusions addition, widespread testing is required for these products to
be accepted by outstanding quality standards.
The chemical valorization of CO2 in the form of a wide The synthesis of polymers by copolymerization of
range of fuels, chemicals and materials through a number of epoxides and CO2 is currently ready for industrial applica-
technologies is challenging but opens new research, indus- tion at large scale. However, despite the relative maturity of
trial and business opportunities. Different technological this technology, there are still opportunities for progress. The
routes for chemical valorization are being developed and copolymerization process needs further research and devel-
approach quickly to commercialization. opment to increase the incorporation of CO2 into the
Different techno-economic and life-cycle studies of dif- copolymers and the scale of polymers production and for the
ferent chemical valorization processes showed that carbon development of catalyst for producing polymers with
dioxide-derived products may have economic and envi- tailor-made features and from renewable epoxides.
ronmental benefits as provide energy saving, greenhouse The technologies for producing building materials by CO2
gas emission reduction and products with similar or carbonation such as CO2-cured concrete and carbonated
improved quality and with smaller carbon and water foot- aggregates are at higher level of development and some pro-
prints and production costs than traditionally produced cesses are being commercialized. These technologies are easy
counterparts. to set up or retrofit in the existing production facilities and
Some technologies for the catalytic, biochemical and generate products with similar or better quality than conven-
electrochemical conversion of carbon dioxide into chemicals tionally produced counterparts with reduced manufacturing
or fuels are already in operation at pre-commercial scale. costs and lower water and CO2 footprints, but the fulfillment
The most technologically mature pathway for chemical of quality standards and end of waste regulations is still
valorization of CO2 to fuels and chemicals depends on the retarding the widespread deployment of these technologies.
Chemical Valorization of CO2 25

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Progress in Catalysts for CO2 Reforming

Maria do Carmo Rangel

Abstract These pollutants are closely related to anthropogenic


activities, mainly those involving the ongoing combustion of
Since the first catalyst proposed for CO2 reforming as
fossil fuels including natural gas and coal as well as
early as 1928 by Fischer and Tropsch, the publications on
light/heavy crude oils during industrial, agricultural, and
the reaction and on catalysts as well as on new
domestic activities. Since pollution causes a severe threat to
applications and technologies have increased continu-
the Earth's sustainability, many policies and legislations
ously. Over the years, new catalysts with several formu-
have been adopted by governmental agencies to avoid or to
lations even more complex have been developed, for
decrease emissions. During the Climate Change Conference
different reaction conditions and for several purposes and
2015 hold in Paris, for instance, it had been agreed that the
applications. Moreover, the most promising formulations
greenhouse gas emissions should decrease to levels enough
have been improved by using new supports and promot-
to limit the increase of Earth temperature to values lower
ers. Also, the knowledge on kinetics and mechanism as
than 2 °C of the temperature before industrialization
well as on the action of supports and promoters has
(UNFCCC, COP21 2015). However, according to the BP
opened opportunities for designing new catalysts for the
Energy Outlook (BP Energy Outlook 2019) the carbon
reaction. In this chapter, the progress on the catalysts for
dioxide emissions from combustion will continuously
dry reforming was discussed over the years, focusing the
increase in the next years achieving around 10% by 2040.
advances on formulations and on the action of the
Based on this projection, the Intergovernmental Panel on
catalysts at different conditions for several applications.
Climate Change recently recommended to limit the global
temperature increase to less than 1.5 °C (Global Warming
and of 1.5 ºC Report).
Although the greenhouse effect has been assigned mainly
1 Introduction
to methane and carbon dioxide (Kischke et al. 2013), it is
known (Baird 1995) that methane is a greenhouse gas much
In the last decades, mankind has faced even more negative
more powerful than carbon dioxide. However, carbon
impacts of pollution on the environment as well as on the
dioxide can remain in the atmosphere for a longer time than
biota. In fact, the frequent discharges of pollutants both in
methane, and then its amount becomes much higher. It has
the water bodies and in the air have greatly contributed to the
been reported (Bong et al. 2017) that the current amount of
water scarcity and to the poor quality of air in several urban
carbon dioxide can remain up to 10,000 years in the atmo-
centers (Rohi et al. 2020; Britto and Rangel 2008; Shah and
sphere causing climate changes. In addition, carbon dioxide
Shah 2020; Rangel and Carvalho 2003). Over the years, the
emissions increase each year and reached 33.1 Gt (an
continuous pollution achieved dangerous levels causing
increase of 1.7%) in 2018, hitting a new record because of
alarming consequences such as global warming and climate
higher energy consumption, as reported by International
changes (Bong et al. 2017; Töbelmann and Wendler 2020).
Energy Agency (IEA International Energy Agency 2018).
Therefore, carbon dioxide has been considered the most
important greenhouse gas, being responsible for the highest
M. do Carmo Rangel (&) percentage of global warming (60%). This pushes all the
Instituto de Química, Universidade Federal do Rio Grande do Sul,
Av. Bento Gonçalves, 9500, Agronomia, Porto Alegre, countries to replace fossil with renewable energy and to look
Rio Grande do Sul 90650-001, Brazil for technologies for the capture, storage, and use of carbon
e-mail: maria.rangel@ufrgs.br

© The Author(s), under exclusive license to Springer Nature Switzerland AG 2022 31


Inamuddin et al. (eds.), Carbon Dioxide Utilization to Sustainable Energy and Fuels,
Advances in Science, Technology & Innovation, https://doi.org/10.1007/978-3-030-72877-9_2
32 M. do Carmo Rangel

dioxide (Mustafa et al. 2020; Saadabadi et al. 2019; Araújo commercial application of carbonaceous materials still
et al. 2008; Ahmed et al. 2020; Galadima and Muraza 2019). depends on overcoming some challenges (Ahmed et al.
Regarding electrical power, the main sources are still fossil 2020).
fuels whose use is expected to increase in the next thirty In line with the development of different methods for
years, achieving triple of the current values before 2100. capture and storage of carbon dioxide, the use of this com-
Therefore, the scientific community has been addressed to pound is essential for keeping sustainable environment.
find out new technologies to use the abundant carbon Therefore, incentives should be provided to industries for the
dioxide coming from fossil fuels (Mustafa et al. 2020; implantation of the Capture, Storage and Use of Carbon
Galadima and Muraza 2019; Zhang et al. 2020). However, Dioxide (CCSU) technologies to convert carbon dioxide into
this largely depends on the technologies for capturing and renewable energy/fuel/chemicals by reusing the industrial
stocking carbon dioxide. emissions (Ahmed et al. 2020). Besides capturing carbon
dioxide from industrial processes and punctual sources, one
should consider other techniques such as the Direct Air
2 Technologies for Capturing and Storing Capture (DAC). This technique uses composite materials
Carbon Dioxide able to sequester carbon dioxide at very low concentrations
to reduce global warming (Ahmed et al. 2020; Song et al.
The technologies for carbon dioxide capture and storage 2019).
(CCS) involve the trapping of this gas from emission units However, the high cost for capturing, transporting, and
(stationary and mobile), transportation, and disposal into storing carbon dioxide largely restrains this technology
geological formations or other places (Ahmed et al. 2020; usage and then the growth of carbon dioxide market. To
Miranda-Barbosa et al. 2017). Different methods were pro- overcome this difficulty, the governments have recently
posed for removing carbon dioxide gas from outlet gases at established regulations and directives on CCS technologies
power stations, including absorption and adsorption (Keller for making them safer and more environmentally friendly.
et al. 2018). The use of amine scrubbing for absorbing This has motivated several companies to develop more
carbon dioxide from flue gas is a common method frequently economically advanced CCS technologies following these
used in powerhouses. Nevertheless, this technology is lim- directives. In addition, an increased number of power plants
ited by the corroding of pieces, the discharge of toxics, and and chemical industries which emit carbon dioxide are
by the high energy consumption during regeneration (Tian installing CCS plants for industrial use (Watch).
et al. 2018). To overcome these drawbacks, several tech-
nologies have been proposed such as starburst, oxyfuel
combustion, and after-combustion combined with tech- 3 Technologies for Using Carbon Dioxide
niques of separation including absorption, adsorption as well
as membranes. Each one has advantages and disadvantages Although carbon dioxide is an abundant and low cost and a
for commercial applications. The absorption based in sol- nontoxic feed, its industrial usage is still difficulty. This
vents, for instance, is recognized as an efficient method but compound is thermodynamically stable, requiring high
requires high amounts of energy, and several dangerous energy that can be provided by co-reagents or electrore-
gases are discharged during the solvent recuperation. This ductive processes. This is probably the main reason for the
has motivated the research for adsorbents in solid phase most preferred use of carbon monoxide instead of carbon
which require less energy, are eco-friendly, and absorb faster dioxide in industrial operations. Indeed, several organic
than liquid absorbents. In addition, they remain unchanged syntheses using carbon dioxide have been studied but only
in severe conditions (Babu et al. 2013). Cost-effective and some of them are used in industry, such as the production of
environment friendly adsorbents such as porous carbons, urea and its derivatives, the manufactory of organic carba-
metal-organic frameworks (MOF), and zeolites, among mates, and the electrochemical Kolbe-Schmitt for salicylic
others, have also been considered. They usually have high acid production (Ma et al. 2009; Alper and Orhan 2017).
specific surface areas and are resistant against water and The market of carbon dioxide usage in 2013 was about
chemicals. The renewable carbon-based materials are espe- 200 MtCO2 per year (Aresta et al. 2013), which can be
cially useful for capturing carbon dioxide due to the high considered small when compared to around 14,000 MtCO2
specific surface area and their hydrophilic and polarity, as per year emitted from big sources (Aresta et al. 2018).
well as to the functional groups on the surface. The Currently, this use tends to increase mainly due to industrial
adsorptive capacity of carbonaceous materials can be easily applications of carbon dioxide, such as refrigeration, food
tailored by modifying the functional groups on the surface and beverages, chemical wholesaling, and pharmaceuticals.
(phenolic carboxylic and amino, others) or by doping their It is expected a growth of 3.9% in the carbon monoxide
surface with other elements. Despite these advantages, the market, achieving USD 9.16 billion by 2026 (Watch). In
Progress in Catalysts for CO2 Reforming 33

addition, carbon dioxide can be used in oil recovery (Dai methane or hydrogen, which will provide the thermal energy
et al. 2014) or as solvent in physical applications such as in for the reaction. To produce methanol and syngas from
supercritical plants (Aresta and Forti 1987). carbon dioxide, for instance, most of the conventional
However, it has been recognized that the most efficient reactions involve hydrogen or methane. There are other
approach is to valorize carbon dioxide by its conversion to hydrogen donors which can be used such as water and
fuels (Jiang et al. 2010) or chemicals (Aresta 2010) just after glycerol (Mustafa et al. 2020). The dry reforming of methane
its capture, using different technologies (Mustafa et al. 2020; and of other carbon-containing compounds is included in
Alper and Orhan 2017), as shown in Fig. 1. The first group this category and will be discussed later. The hydrogenation
includes traditional processes whose energy demands are of carbon dioxide is another kind of reaction in which carbon
provided by fossil sources. They include pure decomposition dioxide reacts with hydrogen to produce methanol (Olah
of carbon dioxide, which requires high energy and an effi- et al. 2008). This traditional approach is the most efficient
cient catalyst, as well as optimized reaction conditions since one in industrial conversion of carbon dioxide to valuable
the reaction is thermodynamically unfavorable (Mustafa chemicals (Mustafa et al. 2020). Other chemicals like ethene,
et al. 2020). Even though, the feasibility of the reaction was ethanol, and formaldehyde can also be obtained by these
demonstrated by some researchers (Yutaka and Bernard processes, but they are not efficient and then other approa-
1986; Itoh et al. 1993) using semipermeable membranes for ches are adopted instead.
oxygen extraction. However, the high values of temperature, The utilization of carbon dioxide as solvent and/or as
the low conversions, and the risk of explosion by the carbon reactant can also be convenient, providing carbon and/or
monoxide and oxygen mixture made this process not oxygen to produce chemicals by several processes. Various
promising for commercial applications (Mustafa et al. 2020). works have demonstrated the advantages of using soft oxi-
Other processes involve reactants with higher values of dants such as carbon dioxide in other reactions like ethane
Gibbs free energy (co-reactant) than carbon dioxide, such as (Saito et al. 2019), propane (Kantserova et al. 2019),

Fig. 1 Traditional and new


technologies for carbon dioxide
conversion (based on Mustafa
et al. 2020)
34 M. do Carmo Rangel

isobutane (Kraemer et al. 2016) and ethylbenzene dehy- formic acid, dimethyl carbonate, cyclic carbonates, copoly-
drogenation (Oliveira et al. 2008; Rangel et al. 2012), along mers, and other compounds of fine chemicals (Alper and
with the dry reforming of methane (Araújo et al. 2008; Alper Orhan 2017). For the industrial production of salicylic acid,
and Orhan 2017) and methane oxidative coupling (Mo et al. polycarbonates, urea, and cyclic carbonates 130 Mt per year
2019). These works and others have demonstrated that car- of carbon dioxide are used, the urea process being respon-
bon dioxide is particularly attractive in the dehydrogenation sible for the most consumption (Alper and Orhan 2017;
of hydrocarbons, which are frequently reversible and limited Aresta 2010).
by equilibrium. The process is carried out at high tempera-
tures to achieve high conversions, but other reactions, such
as hydrocarbons cracking, are favored decreasing the pro- 4 Methane Dry Reforming Process
cess efficiency. The use of carbon dioxide (instead of water)
and a suitable catalyst makes the reaction exothermic Because of the latest findings of abundant reserves of shale
allowing its performance at low temperatures, minimizing gas and the further improvements in hydraulic fracturing
the cracking reaction. In this case, conversion is no more technologies (Coonrod et al. 2020; Klewiah et al. 2020), the
limited by thermodynamic factors (Bhasin et al. 2001). use of methane has been greatly increased worldwide,
As shown in Fig. 1, new processes for the conversion of mainly in the USA. In addition, biomethane has been suc-
carbon dioxide based on renewable sources have also been cessfully obtained from biogas and landfill gas produced
considered, like solar thermochemical, electrochemical, through the anaerobic decomposition of wastes from differ-
biochemical, photochemical, and plasma-chemical. All of ent kinds (Wasajja et al. 2020). This scenario, associated
them have limitations in practical applications. The photo- with the advantages of the abundant and cheap carbon
chemical process is an emerging approach whose challenge dioxide, made the use of methane dry reforming extremely
is to decrease the number of steps, by the selection of favorable. Besides all these advantages, the process con-
appropriated semiconductors. Regarding biological technol- sumes the most important greenhouse gases (Baird 1995).
ogy, the use of microbes is continuously expanding for Through the reaction between methane and carbon dioxide,
converting carbon dioxide into fuels and chemicals, several synthesis gas or syngas (gaseous hydrogen and carbon
microbial species being identified and efficiently contribut- monoxide) can be obtained. The syngas is considered a sus-
ing to the reaction. The electrochemical reduction technol- tainable and alternative fuel to fossil sources, as well as an
ogy is considered a promising process in which the catalyst important feedstock to many processes to produce methanol,
is responsible for the efficiency of reaction. Plasma-chemical dimethyl ether (Saravanan et al. 2017), aromatics (Yang et al.
technology has been used for carbon dioxide conversion 2020), olefins (Zhao et al. 2018), ethanol (Xu et al. 2017a),
through cold and thermal plasma, the last one being con- higher alcohols and other high-value chemicals by Fischer–
sidered the best option for dry reforming. The production of Tropsch synthesis (Panzone et al. 2020). The last reaction is
oxygenates by the process of plasma-chemical looks the most used process worldwide to convert syngas to liquid
encouraging but needs to be more investigated. The process fuels to avoid the inconvenience of storing and transporting
of solar thermochemical technology seems to be promising gaseous fuels. Each chemical can require feedstocks with
for using concentrated solar energy, which is commercially different hydrogen to carbon monoxide molar ratios that can
used for power generation and for the reaction of carbon be adjusted by the water gas shift reaction (Rangel et al. 2017).
dioxide and hydrogen to produce syngas, which can further As shown in Eq. 1, methane dry reforming is endother-
produce liquid hydrocarbons (Mustafa et al. 2020). mic and is frequently performed at temperatures above700 °
The potential of homogeneous catalysis to produce C to obtain suitable conversions. According to stoichiome-
high-value chemicals has been demonstrated. Carbonates, try, hydrogen to carbon dioxide (H2/CO) of 1.0 is expected
carbamates, urethanes, lactones, and pyrones, as well as for- but other parallel reactions also occur (Eq. 2–6). The
mic acid and derivatives, can be obtained using homogeneous decomposition of methane (Eq. 2), the disproportionation of
catalysts. On the other hand, heterogeneous catalysis can be carbon monoxide (Eq. 3) and the hydrogenation of carbon
technically more advantageous like the ease reactor, design dioxide (Eq. 4) and of carbon monoxide (Eq. 5) are unde-
and easier carrying on, recovery and reutilization of the cat- sirable reactions that lead to coke formation on the catalyst.
alyst (Ma et al. 2009). However, these approaches demand The reverse water gas shift reaction, RWGSR (Eq. 6), cau-
carbon dioxide activation by heterogeneous catalysts. ses the lowering of hydrogen to carbon dioxide molar ratio
The viability of carbon dioxide as a feed for chemical to lesser than 1.0, since it consumes carbon dioxide (Wang
processes has been pointed out some years ago by the pro- et al. 1996; Zhang et al. 2018a).
duction of C1 building block chemicals (Bertau et al. 2010;
Ola et al. 2013; Aresta and Dibenedetto 2007), such as urea CH4 þ CO2 ! 2CO þ 2H2 DH298K ¼ 248 kJ mol1 ð1Þ
(commodity), formaldehyde, methanol, ethylene carbonate,
Progress in Catalysts for CO2 Reforming 35


2CO $ C þ CO2 DH298K ¼ 172:6 kJ mol1 ð2Þ found severe carbon formation and then the deactivation of
nickel and cobalt-based catalysts. Twenty years later, Reit-
CH4 ! C þ 2H2 DH298K ¼ 75 kJ mol1 ð3Þ meier et al. (1948) have demonstrated the advantages of using
carbon dioxide to control the hydrogen to carbon monoxide
CO2 þ 2H2 $ C þ 2H2 O DH298K ¼ 90 kJ mol1 ð4Þ ratio in the synthesis gas obtained by steam reforming of
methane (Eq. 7), without producing coke. By equilibrium
H2 þ CO $ H2 O þ C DH298K ¼ 5a1:3 kJ mol ð5Þ considerations, as well as by laboratory and pilot plant
investigations over a nickel catalyst supported on a perforated
CO2 þ H2 $ CO þ H2 O DH298K ¼ 41:2 kJ mol1 ð6Þ disk, they have found the reaction conditions in which the
syngas composition could be adjusted by changing the feed-
These reactions can be controlled by the temperature of dry
stock composition. This was the first work that pointed out the
reforming since each reaction has lower and upper limits to
suitable conditions to obtain H2/CO ranging from 3 to 0.5 to be
occur. For instance, at values above 640 °C methane cracking
used in Fischer–Tropsch synthesis for different purposes.
begins to occur while carbon monoxide disproportionation
Depending on these values, the excess carbon dioxide in the
(Eq. 2) and the RWGS (Eq. 6) are inhibited above 820 °C. In
effluent gas could be recovered and recycled to the reactor.
the 557–700 °C range, methane cracking and carbon
These results were used to build an industrial plant for the
monoxide disproportionation are favorable and then carbon
Bureau of Mines at Bruceton, Pennsylvania, USA.
deposition occurs. In addition, methane dry reforming is
limited by equilibrium and is favored at temperatures CH4 þ H2 O ! CO þ 3H2 DH298K ¼ 206 kJ mol1 ð7Þ
above727 °C. In these conditions, the disproportionation of
carbon monoxide (Eq. 2) is inhibited whereas methane Table 1 shows the reports on dry reforming in the period
cracking (Eq. 3) will occur. At this condition, methane from 1928 to 1989. It can be noted that few works have been
cracking is the major responsible for deactivating the catalysts carried out, most of them showing simple formulations of
by coke deposition (Wang et al. 1996; Zhang et al. 2018a). catalysts. In this period, the research has been addressed to
Several studies have been performed on thermodynamic find catalytically active metals or compounds. Only the
simulations for different conditions of temperature (Wang commercial catalysts for steam reforming have included
et al. 1996; Jang et al. 2016; Nikoo and Amin 2011), CO2/CH4 mixed supports or dopants. In fact, until 1990, most of the
ratio (Nikoo and Amin 2011), pressure, and additional oxidant research was addressed to steam reforming, the most
(Wang et al. 1996; Jang et al. 2016), taking the contribution of important industrial route to produce syngas and hydrogen
the reactions responsible for coke formation into account since that time. However, in the following years, the interest
(Nikoo and Amin 2011). It was concluded that the best for dry reforming has been increasingly motivated by the
operation conditions for methane dry reforming are tempera- incentives to consume carbon dioxide for decreasing global
tures higher than 850 °C and low pressures to achieve higher warming and to develop technologies to produce clean
conversions (Wang et al. 1996; Jang et al. 2016; Nikoo and energy. In addition, it has been recognized the advantages of
Amin 2011). In addition, carbon formation should be avoided producing syngas with low hydrogen to carbon dioxide ratio,
to operate the process stably (Wang et al. 1996; Jang et al. proper to Fischer–Tropsch synthesis, to obtain hydrocarbons
2016; Nikoo and Amin 2011). Moreover, these works have or oxygenates.
demonstrated that one cannot predict the conversion or coke
formation by thermodynamic calculation, because the rate
reactions strongly depend on the selectivity of the catalyst. 4.2 Progress in Catalysts for Methane Dry
Besides the thermodynamic requirements, the occurrence Reforming (1990–1999)
and the extension with which the Eqs. 1–6 occur largely
depend on the selectivity of the catalyst. Therefore, a lot of The first works in the 1990s have been motivated by the
work has been carried out over the years, aiming to find need of using dry reforming in the Chemical Energy
active, selective, and stable catalysts, which cannot go on Transmission Systems (CETS) for energy storage and
deactivation. transmission. Richardson and Paripatyadar (1990), for
instance, have evaluated a noble-based catalyst (0.5 wt.%
Rh/c-Al2O3) in a pilot plant and have proposed a model for
4.1 Progress in Catalysts for Methane Dry methane conversion, incorporating the rate and the internal
Reforming (1928–1989) and external diffusion equations. The catalyst has shown no
coke deposition during dry reforming and has been suc-
The first detailed investigation dealing with dry reforming was cessfully tested in large scale experiments in solar receivers.
reported in 1928 by Fischer and Tropsch (1928), who have The choice of rhodium was based on the experience with
36 M. do Carmo Rangel

Table 1 Progress in catalyst Active phase Support Reference


development (1928–1989)
Ni, Co Fischer and Tropsch (1928)
Ni, CuO, Fe2O3 SiO2 Sodesawa et al. (1979)
Rh > Pd > Pt  Ru Al2O3 Sakai et al. (1984)
Ni > Co  Fe Al2O3 Tokunaga and Ogasawara (1989)

noble metals in steam reforming, which showed that rho- Other researchers have reported strong effects of
dium and ruthenium were ten times more active than nickel, acidity/basicity of support on the catalysts' performance.
platinum, and palladium (Rostrup-Nielsen 1983). Although Gronchi et al. (1995), for instance, have proposed that the
nickel has been the most economical and used catalyst in basic sites of lanthana were able to activate carbon dioxide,
commercial processes of steam reforming (Ridler et al. inhibiting carbon deposition on rhodium-based catalysts.
1989), it requires a lot of steam (to control coke deposition) Lercher et al. (1996) have also considered the role of the
which decreases the efficiency of the CETS (Richardson and acidity of the support on the catalyst efficiency and have
Paripatyadar 1990). found a proportionality between the rate of coke production
Table 2 shows the progress on the catalyst development and the concentration of Lewis sites on the support. In line
from 1990 to 1999. During this decade, the studies have with these findings, Zhang et al. (1996) have considered that
been addressed to investigate new supports (pure or mixed) the acidity of the support could affect the performance of
that could interact with the metal and improve its catalytic rhodium-based catalysts as well. They have found that the
properties. In addition, the first studies have suggested initial intrinsic activity largely depended on the support
possible other roles of the support besides providing the acidity, as suggested by the decreasing sequence:
dispersion of metal particles. Moreover, the dopants have yttria-stabilized zirconia (YSZ); Al2O3; TiO2; SiO2; La2O3
begun to be used mainly in the supports. and MgO. Moreover, as the metal nanoparticle size
Therefore, other supports have been evaluated, such as increased the catalyst activity and velocity of deactivation
europium oxide, Eu2O3 (Perera et al. 1991), for ruthenium or diminished. The catalysts based on titania and magnesia
iridium, the catalysts proving to be active and producing no have shown the highest deactivation rates while those based
significant coke after several cycles. They have shown on YSZ and silica showed no deactivation during 50 h on
similar performances as compared to alumina-based cata- stream. The catalyst deactivation has been caused by coke
lysts (Ashcroft et al. 1991), suggesting that the kind of formation, sintering of the metal, and rhodium poisoning by
support did not affect the catalytic mechanism. Mark and some species of the support. These effects on activity and on
Maier (1996) have come to the same conclusion studying deactivation were found to be dependent on the support,
rhodium, ruthenium, and iridium supported on alumina, suggesting that they are related to its interaction between
titania, silica, and zirconia. However, silica, titania, and metal and support. In a further paper (Efstathiou et al. 1996),
alumina have been also evaluated by Nakamura et al. (1994), the same group has investigated the dry reforming mecha-
who have noted a significant decrease in activity from rho- nism over YSZ and alumina-supported rhodium. This was
dium supported on alumina to silica, titania showing an the first report of experimental results for dry reforming
intermediate value. In another work, Bitter et al. (1996) have derived from steady-state tracing, allowing to prove the
found the following order of stability of platinum on dif- origin of carbon species accumulated on rhodium surface
ferent supports: Pt/c-Al2O3 < Pt/TiO2 < Pt/ZrO2. This ten- catalysts. It has been concluded that the YSZ-based catalyst
dency was related to coke deposition blocking the active was the most resistant against carbon deposition because the
sites. In addition, it has been noted that for platinum-based ability of the support for providing lattice oxygen species,
catalysts the active sites are located in the interface of metal which react with carbonaceous species. These species could
and support. This was confirmed in another study (Bitter spill over rhodium, favoring the formation of carbon
et al. 1998) by steady-state transient kinetics measurements monoxide and water.
and other techniques. These contradictory results are prob- The role of the support in affecting the metal activity has
ably associated with different reaction conditions as well as been also investigated at molecular level (Basini and San-
different catalyst preparations. In a further report, Bitter et al. filippo 1995). The experiments were performed over rho-
(1999) have pointed out that the rates of carbon formation dium, ruthenium, and iridium as a monolayer deposited on
and of deactivation depend on the stability of carbonates a-alumina, magnesia, ceria, lantana, and titania with low
coming from carbon dioxide on the supports. The replace- surface areas. It has been found that carbon dioxide could be
ment of zirconia by alumina decreased the stability and partially dissociated producing oxidic and carbonyl species
favored the growth of carbon particles. on metal surfaces. This reactivity was facilitated by surface
Progress in Catalysts for CO2 Reforming 37

Table 2 Progress in catalyst development for dry reforming (1990–1999)


Active phase Support Promoter Reference
0.5 wt.% Rh c-Al2O3 Richardson and Paripatyadar (1990)
Ru, Ir Eu2O3 Perera et al. (1991)
Ru, Ir Al2O3 Ashcroft et al. (1991)
Ir, Rh, Ni > Pd > Ru Al2O3 Vernon et al. (1992)
MnO2 Mirzabekova et al. (1992)
CeO2 Otsuka et al. (1993)
Ru, Rh > Ir > Ni, Pt, Pd Al2O3-stabilized MgO Rostrup-Nielsen and Hansen (1993)
Rh > Ru > Ir > Pt > Pd MgO Qin and Lapszewicz (1994)
Re c-Al2O3 Claridge et al. (1994)
Rh Al2O3 > TiO2 > SiO2 Al2O3, TiO2, Nakamura et al. (1994)
MgO
Ni Al2O3 La Blom et al. (1994)
Ni Al2O3 Pt, Rh-, Inui et al. (1994)
CeO2, La2O3,
Ni, Pt ZrO2 > c-Al2O3 > a-Al2O3 K Seshan et al. (1994)
Ni SiO2, La2O3, MgO, ZrO2, TiO2, Al2O3-SiO2 Cu, K Swaan et al. (1994)
Co SiO2 > AC MgO Guerrero-Ruiz et al. (1994)
Ni MgO, SiO2 SiO2, MgO Takayasu et al. (1995)
Ni Al2O3, SiO2 MgO, CaO Tang et al. (1995)
Ni MgO, CaO, BaO, SrO Ruckenstein and Hu (1995)
Rh, Ru, Ir Al2O3, TiO2, SiO2, ZrO2 Mark and Maier (1996)
Pt Al2O3, TiO2, ZrO2 Bitter et al. (1996)
Rh YSZ > Al2O3 > TiO2 > SiO2 > La2O3 > MgO Zhang et al. (1996)
Pt, Ni TiO2, ZrO2, Al2O3 Lercher et al. (1996)
Ni, Cu, Co, Fe, Ru, Rh, MgO, TiO2, SiO2, Activated Carbon, Cr2O3 Bradford and Vannice (1996a), Bradford and Vannice
Pd, Ir, Pt (1998), Bradford and Vannice (1999)
Ni La2O3, c-Al2O3, CaO Zhaolong and Verykios (1996)
Ni Al2O3 MgO, CaO, Cheng et al. (1996)
La2O3, CeO
Ni a-Al2O3 Fe, Co, Cu, Halliche et al. (1996)
Ce
Ni Al2O3 Na, K, Mg, Horiuchi et al. (1996)
Ca
Ni Pentasil-type zeolite K, Ca Chang et al. (1996)
MoS2, WS2 Osaki et al. (1997)
Ni0.03Mg0.97 Pt, Pd, Rh Chen et al. (1997a)
Rh NaY > HY Bhat and Sachtler (1997)
(Rh > Pt > Ir, Pd > Ru) ZrO2 Keulen et al. (1997)
Pt SiO2, ZrO2 Sn Stagg and Resasco (1997)
Ni Al2O3 La–Nd–Pr Slagtern et al. (1997)
Ni–Mg–O Cr2O3, La2O3 Chen et al. (1998)
Ru Activated carbon MgO Ferreira-Aparicio et al. (1998)
Pt ZrO2 Ce, La Stagg and Resasco (1998)
Ni CeO2–Al2O3, CeO2 Wang and Lu (1998)
Ni Al2O3 MoO3 or York et al. (1998)
WO3
Rh SiO2 V Bradford and Vannice (1999)
38 M. do Carmo Rangel

hydrogen atoms produced by dissociative hydrogen or (1995), doping nickel-based catalysts with alkaline earth
methane chemisorption. The reactivities of the hydridocar- metal (magnesium, calcium, barium, and strontium) oxide.
bonyl and oxidic species were considered as the center of the The NiO/MgO catalyst was superior to the others, a fact that
catalytic cycle, during which one species was periodically was related to a nickel oxide and magnesium oxide solid
converted into the other one. The carbon growth reactions solution. In addition, Stagg and Resasco (1997,1998) have
have been inhibited by the high oxidative properties of the noted that tin, cerium, and lanthanum were efficient pro-
noble metal-oxygen adducts. moters for silica or zirconia-supported platinum for pre-
In addition, Bradford and Vanice (1996a,1998) have venting deactivation. In another work (Slagtern et al. 1997),
studied the metal-support interaction in nickel deposited on it has been found that different loadings of a rare-earth
magnesia, titania, silica, and on activated carbon (AC). Less mixture (La, Nd, Pr) or of pure lanthanum could efficiently
coking was noted for titania and magnesia-supported nickel, increase the catalytic activity of alumina-supported nickel as
the last one being active and stable for 44 h on stream. The well as its stability. Moreover, York et al. (1998) have found
strong interaction of nickel and titania provided TiOx species that by adding molybdenum oxide (MoO3) or tungsten
that decorated the surface of metal particles and then (VI) oxide (WO3) to nickel supported on alumina, carbon
destroyed the big ensembles of nickel, responsible for coke formation was strongly decreased, the tungsten-containing
formation. On the other hand, the nickel oxide-magnesium samples showing no deactivation.
oxide solid solution stabilized the reduced nickel, making Besides promoting the support, other studies have been
them resistant against coke formation. Moreover, the authors carried out promoting the active phase. Halliche et al.
proposed that the activity of the metal could be affected by (1996), for instance, have found that the activity of nickel
the support, changing the ability of reduced nickel for supported on a-alumna changed in the order: nickel
donating electrons. In a further work (Bradford and Vannice * nickel-cobalt, nickel-cerium > níckel-copper  nickel-
1999), they have elucidated the role of the support by iron. The action of these additives has been assigned to the
studying several metals (copper, cobalt, iron, nickel, ruthe- interaction of nickel with the other metals. Sometime later,
nium, rhodium, paladium, iridium, and platinum) deposited Chen et al. (1997a) have evaluated the effects of doping both
on silica or titania. It was found that both the support and the metal and support on the catalysts' performance by using
percentage of d character of each metal affected the activity, different amounts of Pt, Pd, and Rh on the catalysts based on
different trends being observed for metals on each support. the Ni0.03Mg0.97 solid solution. An appreciable improvement
For silica, platinum showed the highest activity while in activity and stability was noted, the last one being related
ruthenium exhibited the maximum activity for titania. to the increased nickel reducibility. Moreover, Chen et al.
At that time, rhodium has seemed to be the most suitable (1997b) have found that small amounts of trivalent-metal
catalyst to dry reforming, but the high cost and low avail- oxides (Cr2O3, La2O3) have improved the resistance against
ability have pushed the investigation to improve the coke on Ni–Mg–O catalysts. This finding was related to the
nickel-based catalysts and to look for other active phases. In ability of the dopants to create Schottky defects that
line with this need, Swaan et al. (1994) have considered the increased the oxygen anions mobility in the lattice, fastening
use of different supports and dopants, by studying nickel the oxidation of carbonaceous species. In addition, part of
supported on silica, lantana, magnesia, zirconia, titania, the Schottky defects (cationic vacancies) may go to the
alumina-silica, and potassium, and copper as dopants for surface and favor nickel reducibility.
silica. The low activity of the catalysts based on magnesia, Another strategy adopted to improve the dry reforming
titania, and potassium-doped silica was related to the catalysts was the physical mixture of different metal oxides
metal-support interactions which have made nickel reduction and the catalysts, such as the study of Takayasu et al. (1995).
more difficult. This led to the conclusion that the activity of They have found that the addition of silica to magnesia-
nickel was more related to nickel phase on each support. supported nickel increased the activity and the resistance
Other dopants, such as magnesium oxide and/or calcium against coke deposition, while no effect was noted for the
oxide, have also been investigated for alumina and addition of magnesia, at 800 °C. It means that magnesium
silica-supported nickel catalysts (Tang et al. 1995). The oxide improved the activity as a support but not in a mixture.
dopants improved silica-supported nickel, a fact that was The physically mixed silica decreased the amount of
related to their basic character, depressing carbon deposition. deposited coke, this being related to its ability of storing
Horiuchi et al. (1996) have come to the same conclusion by hydrogen and of spillover the CHx adsorbed species, pre-
studying the role of basic metal (sodium, potassium, mag- venting carbon deposition.
nesium, and calcium) oxides on deactivation of alumina- The role of promoters has also been studied on
supported nickel. It has been proposed that the promoters cobalt-based catalysts (Horiuchi et al. 1996) using silica and
decreased nickel activity in methane dehydrogenation. This activated carbon as supports in the range of 500–700 °C.
effect has also been investigated by Ruckenstein and Hu The role of the promoter was assigned to strongly adsorbed
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what had caused her to be so.

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week; but that can't be in here."

"No," she said, "it was much longer ago. Think, Captain
Fortescue; did you never lose a letter that you wanted very
much to find? Was a letter never stolen from you by some
one? And have you not tried in all ways to find that letter,
but in vain?"

He understood now: all the colour had faded from his


face. Was it possible, could it be that his father's letter had
been found—and by her?

"Is it in this box?" he asked.

"Yes; I do hope it is the right one. Will you open it and


see?"

He cut the string which she had knotted tightly round it:
he drew out the paper; he saw his father's well-known
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Yes, it was evidently the letter which he ought to have


found in that envelope in the safe, the envelope of which
was still in his possession, and which was addressed, "For
my son, To be opened after my death."

"Is it the right one?"

"Yes, it is, Miss Douglas. How can I thank you?"

"May I tell you how I found it? And then I must go."

She knew how he was longing to read the letter, and


she thought that he would want to read it alone. Her one
desire was to tell him how it had come into her possession,
and then to leave him. But he would not hear of her doing
this; he made her sit down again, and, before she could
stop him, he rang the bell for Mrs. Hall, and told her to
bring another cup, that she might have some tea before she
left.

Then Marjorie told him her story as shortly as she


could. She spoke of old Mrs. Hotchkiss's unhappiness during
her illness; she told him of her midnight call to the old
house, and of the secret that had then been told her. She
described the place in which she had discovered the box;
she confessed that she had broken the seals and opened it,
that she might see the name at the end of the letter, and
might know whether Mr. Forty Screws and Mr. Fortescue
were the same. And now she said, as she got up from her
chair again, she was thankful, very glad and thankful that it
was safely in his hands, and she must go; she really must
go. She knew how he was longing to read it, and she would
not keep him another moment.

"Miss Douglas," said Captain Fortescue, "I am not going


to allow you to leave until you've had some tea, and then I
am going with you to the station. But if you are sure you do
not mind, I will just read the letter, and then I shall be able
to tell you what it is about, and for what I have to thank
you."

When she saw that it was of no use to protest any


further, she sat down again by the fire, and he took a chair
to the table, and by the dim light of the solitary gas-burner
sat down to read the letter. She glanced at him from time to
time as he bent over it, wondering as she did so what its
contents might be, looking anxiously to see the effect upon
him as he read. Every vestige of colour had faded out of his
face, but he read on intently, and without once looking up.
Marjorie could hear the clock in the passage ticking loudly,
but no other sound disturbed the stillness of the room. He
did not speak a word, nor utter a sound, till he turned to
the last page, and then he gave a loud exclamation of
dismay.

"Is it bad news?" she asked fearfully.

"No, not bad news; it is good news, very good news,"


he said, "but those rascals have tampered with the letter."

He held it up to her, and she saw that one word, a long


word too, had been completely blotted out.

"It has evidently been done on purpose," he said, "lest


this letter should by any means fall into my hands."

"Is the word of much importance?"

"Of every importance; in fact, it is the most important


word in the whole letter. Miss Douglas, we will have some
tea, and then I want you, if you do not mind, to read the
letter you have brought."

"May I? But are you sure you would like me to read it?"
"I am quite sure; indeed, so far from minding it, I am
most anxious that you should read it."

He put the armchair near the table for her, and began to
pour out the tea, but his hand trembled so much with
strong emotion that she asked him if she might do it for
him. He told her that, if she did not mind doing it, he should
like to remember it, after she had gone; it would be
something to think of when he was alone.

"It's rather different to the last tea we had together," he


said; "that cosy tea in Fernbank. If I had known you were
coming, I would have had some cake!"

But at that moment Mrs. Hall came into the room with a
hot tea-cake in her hand.

"I've just baked 'em, sir, and they're nice and light, and
I thought, as the lady was here, perhaps you would accept
of one."

"Thank you, Mrs. Hall; it looks delicious!" They did not


talk much during tea; his mind was on the letter he had just
read, and he asked her from time to time to give him
further details of the history which she had heard from Mrs.
Hotchkiss. He had no doubt whatever that Makepeace was
the man who had married Carrie Hotchkiss, and he
remembered hearing that Watson had a half-brother living
in Sheffield. Evidently, then, he had been right in his former
suspicion; Watson had undoubtedly been the thief. She
must have been listening at the bedroom door when his
father told him to look under the will in the safe for the
important letter which he wished him to receive.

Then, when she found herself alone with the old man
for the night, she must have taken the keys from the table
whilst he was asleep, unlocked the safe, and taken out the
letter, replacing it, either then or afterwards, by a blank
sheet of foolscap paper. Then, when she had satisfied her
curiosity, and had also discovered the importance of its
contents, she had evidently carried the letter to Makepeace,
and the brother and sister must have plotted together that
they would keep it back, in the hope that they might be
able to make it a kind of gold mine, were they fortunate
enough to discover the father who had deserted his infant
child.

They could not help being aware that the information in


the letter was of such a nature that it would be of the
utmost importance to that man to have it suppressed.

Then, after that, Watson must have found that other


letter, the one Makepeace had brought him, lying unposted
on the table, and then either she or her brother must have
invented the plausible story which Makepeace had told him,
in order to prevent any suspicion from falling upon Watson.

All this probable explanation of the strange mystery


flashed through Kenneth Fortescue's mind more quickly
than it can be told here, and Marjorie could see that from
time to time his thoughts were far away, although he
always seemed to notice in a moment if she wanted
anything, and he was not content until she had done justice
to Mrs. Hall's tea-cake. He ate very little himself, and, as
soon as she had finished, he drew her chair nearer to the
fire and handed her the letter.

"Are you quite sure you want me to read it?" she asked
again. "Do say if you would rather I did not."

"It will be a comfort to me if you do not mind reading it,


Miss Douglas."
She could not refuse after that. She unfolded the large
sheet and began to read.

CHAPTER XVII
A STRANGE LETTER

THE letter which Marjorie held in her hand was badly


written and spelt, but she was able to decipher most of it.
And this is what she read—

"MY DEAR KEN,

"I feel as if I might not live for many years


longer, so I am writing this, that you may be
able to read it when I am dead and gone. I feel
as if I ought to let you know; and yet I
promised him to keep his secret as long as I
lived, all the days of my life, them was the
words as he made me say. But I didn't promise
not to tell when the days of my life was over,
Ken, and they will be over when you get this
'ere letter.

"Well, Ken, I'm a-going to tell you something


that happened to me about twenty-five years
ago. I heard as there was good luck to be had
out in South Africa; so me and your ma talked
it over, and we settled we would go out there
and make our fortunes. We had saved a bit of
money, and we paid our passage, and we went
out, and we got on pretty fair. The work was
good, and so was the pay, but things was a lot
dearer out there than at home.

"I worked on, Ken, first in one place and then


in another, and at last we settled down near
some mines not far from Kimberley. There were
a lot of miners there, a rough set most of them,
and the life was a pretty hard one. I made good
money there, though I spent it pretty nigh as
fast as I made it. We got a decent sort of a
house, and your ma took a pride in it, and I
bought some furniture of a man who was going
to England, and we fed on the fat of the land. It
was when we was there that I got a man, who
had been a painter afore he left England, to
paint a big picture of my missus, and I paid him
well for doing it. That's it as hangs in the
library, Ken. Well, it was while we was living
there in a ramshackle sort of town, that one
night, after dark, Jack McDougall, him as kept
the Inn there, came to our house.

"'Joe,' he says, 'here's a nice job we're in for


at our house. Here's a gent, as is travelling on
to Kimberley, and he came to our house with a
lady last night, and now there's the lady ill in
bed, and a little baby born in the night. And
doctor, him from over yonder, has just been
here, and he says she's very bad and going to
die.'

"'That's a bad job, Jack!' I says.


"'Yes, Joe,' he says, 'and my missus is that
scared she don't know what to do, and there's
nobody else about but old Nurse Grindle, and
she's half drunk. So I came across to see if your
missus would come over and help us a bit.'

"Well, your ma went; she were that handy


when folks were ill, and she did what she could
for the poor lady; but it weren't of no use, and
the next day she died. My missus was fair cut
up when she had passed away; she said she
had the prettiest face and the loveliest hair she
had ever seen, and she looked so young too!
Your ma brought the baby over to our house,
such a poor little thing it was! Doctor said he
didn't think it had a chance to live. Well, we
said we would keep it till after the funeral, but
that night, when I was just a-going to bed, I
heard some one at the door.

"I went down, and there was a fine-looking


gentleman, the handsomest man I've ever seen
excepting one, and that's yourself, Ken! I
guessed it was the baby's father, and I asked
him if he would come in. I thought he had come
to fetch his child, and I told him my missus had
taken it up to bed, but I would tell her he had
come for it. He said, 'No, he hadn't come for the
baby; but he had come to talk to me.' So I
asked him in, and we sat over the fire together.

"He did not speak at first, and then he said,


'How would I like to be a very rich man?' I said
as how I would like it very much, nothing
better. And then he said he could put me in the
way of being one if I liked; he could make a
gentleman of me, and I would never have to
work any more. You can think I opened my ears
then, Ken, and I asked him how he was going
to manage it, and what he wanted me to do. He
didn't answer for a bit, and then he said he
would tell me. He wanted me and my missus to
take charge of the baby.

"'For how long?' I asked.

"'For always,' he said. 'I want it to stop with


you altogether, if so be that it lives, which it
won't do; the doctor gives it three months at
most. Still, there's just the chance it may! So I
want you to adopt it, in fact,' he says.

"I thought it was awfully queer of him, Ken,


to want to get rid of his own child; it seemed to
me unnatural-like, so I asked him why he did it.
He told me he was in a bit of a difficulty, and
this would help him out of it. I said I wouldn't
do it unless he told me what the bother was. So
then he went so far as to say his father had
written him a letter, and that letter obliged him
to do it. But I wasn't satisfied, Ken; I said I
must know what the letter was about, and then
it all came out.

"'His father, he said, was a very wealthy man


in England, who had married an American lady
with a big fortune of her own. His father had a
grand estate somewhere, and of course he was
the heir to it; his mother was dead, and all her
money, having been settled on herself, had
come to him; but of course it was nothing to
what he would get when his father died.
However, his father had married again about a
year ago, and this second wife had a child, also
a boy.

"Then he went on to tell me that his father


had for a long time set his heart on his
marrying a lady who owned the next estate.
She had one of the biggest rent-rolls in
England, and if he married her, they would own
the whole county between them. She was older
than he was, but he had no objection to
marrying her now, in fact, he thought it was the
best thing he could do; but of course she would
never dream of having him, if she had any idea
that he had been married before, or had a child
living who would be heir to his title and estates.
I asked him why he had objected to marrying
this lady before, and he said it was because he
liked some one else better,—this wife of his who
had just died.

"He had been married abroad, and his father


knew nothing about her. She was the daughter
of a Chaplain at one of the places he had
stopped at. I told him if he was so fond of his
wife, he ought to be fond of her child; but he
said the child had cost her her life, and how
could he bear to look at it? He felt as if he never
wanted to see it again. Besides, it was no use
talking about the child. If he was to take it back
to England (and how could he possibly travel
with so young a baby?) what would his father
say? He had had a letter from his father, in
which he told him that, if he didn't do as he
wanted him about marrying this girl (or this
woman, whatever she was) that lived near
)
them, he would leave all his money to the little
boy—the child of his second wife. He couldn't
leave him the title or the estate; they had to go
to the eldest son; but he could leave his money
to whoever he liked.

"Well, Ken, he talked and he argued half the


night, and at last I called my missus, and told
her to get up and come downstairs. She didn't
like the thought of it at first; it seemed like
cheating the poor child, she said, and keeping
him out of his rights. But he offered us a big
sum of money, a fortune, Ken, half of what he'd
got from his mother, that rich American lady, if I
would only say I would keep the child, and at
last me and my missus came round. She told
him he was a heartless man, and she didn't like
doing it; but you see the money was a big
temptation, Ken. Never to have to work any
more and to live like grand folks, seemed
almost more than we could put aside. And then
we had no children of our own, and the missus
had always wanted one, and she were kind of
wrapped up in this little baby.

"Well, the end of the matter was, that we said


we would consent, and then he made me take a
solemn promise that I wouldn't ever tell
anybody that it wasn't my own child, but that I
would keep his secret all the days of my life.

"He asked me then what my name was, and I


said Tomkins, and he laughed and said, 'Give
the poor little beggar a better-sounding name
than that. Change your name, Tomkins,' he
says, 'to something that sounds a bit more
y g
aristocratic than that.'

"'What shall it be, sir?' I says. 'I'm not going


to tell you, Tomkins, nor do I want to know,' he
says. 'Get a pen and I'll write you out a cheque;
but no, that won't do!' he says. Then he sits
and thinks a bit. You see, Ken, he didn't want
me to know his name nor who he was, and the
cheque would have told me. 'I know,' he says at
last, 'I'll cash the cheque myself, and bring you
the money; they can easily wire to my English
bankers from the Kimberley Bank, and they'll
find it's all right.'

"So a day or two after that he brings the


money, Ken,—a great roll of notes it was, and
each note was for £100. He counted it all out,
what he'd agreed to give me; and then he said
he was going to give me £5000 extra, for the
poor little beggar, in case he lived. He would
like him to be educated as a gentleman, he
said. I think his conscience had smote him,
Ken.

"Well, I promised that I would do the best I


could for the baby, and then my missus said
should she fetch it, that he might give it a kiss,
but he said No, he thought he had rather not
see it. He was a heartless man,—very.

"Then I asked him, Ken, if I might know his


name and address, in case I had anything to
tell him about the baby. How could I let him
know if it died or anything happened to it? But
he said there was no need to let him know, and
he did not intend to tell me his name. I had got
g
my money, and what more did I want?

"Well, he got up to go, and I helped him to


put on his coat, for it was raining when he
came, and then I noticed for the first time that
he had something the matter with his hand; the
last joint of the little finger of the right hand
was gone. After that he went away, and I've
never seen him, Ken, from that day to this. I
went to the Inn, and I found that there he had
given the name of Vavasour, but I feel sure that
was not his right name; he was far too clever
for that.

"However, some time after, I came across a


man who had travelled out with him from
England—at least I think it must have been the
same, from this man's description of him and
his wife. He told me that these people he had
met were going out to South Africa, and he
wondered whether they had ever come to
Kimberley. He told me that the man was a lord,
and that some one on board ship, who had seen
him before, said that he was the son of—"

Here came the word or words which had been so


carefully blotted out.

"Now, Ken, what I've got to tell you is this.


That man was your father, and you are that
poor little deserted boy. I've done my best for
you, Ken; you know as I have. I had a hard
time with you at first, for we started off for
England when you was about two months old,
and before we got halfway home, my poor
missus died, your ma as you have always called
her; and there was I on board ship, left with a
tiny weakly baby.

"But I reared you, Ken, and you lived and


grew strong, in spite of yon old doctor at
Kimberley, and now you're a fine handsome
young man, and I love you as if you was my
own son. But I would like for you to have your
rights, Ken. Find that man if you can, and tell
him he's your father. If he has any conscience,
(he hasn't much, I'm afraid), he'll be obliged to
own you, when you show him this letter, and
tell him how you got it. And mark this, Ken,
you're as like your father as two peas are like. I
mean to say you're like what your father was
when I saw him. Now he will be a man over
fifty, I should say.

"Follow this up, Ken, and don't rest till you're


got your rights.

"Your loving father,

"JOSEPH
FORTESCUE.

"P.S.—I chose Fortescue because I thought as


it sounded like the name of a gentleman."
CHAPTER XVIII
WORDS TO BE REMEMBERED

MARJORIE did not speak whilst she was reading the


whole of that long letter, and Kenneth Fortescue sat and
watched her, just as before she had sat and watched him.
He saw her face flush as she read on, and once he felt sure
that he saw a tear drop on the page. When at last she
handed him the letter, she said—

"How could he be so cruel? It was awfully heartless,


wasn't it?"

"Yes, it was most unnatural; but such things have been


done before. Even a mother has been known to desert her
own child."

"I wonder if he is alive."

"So do I. If only that word had been there!"

"Let us look at it carefully," Marjorie said; "perhaps we


can make it out."

They bent together over the paper, as they held it in the


light of the lamp.

"It must be a very long name," she said. "Can it all be


one word? I think Lord is the first part of it. That looks to
me like part of the loop of the L left above the blot."

"Yes, I think you are right. Even so, I think it is a long


name—ten or twelve letters, I should say."
"Oh, I wish we knew!" said Marjorie.

"I wish it very much for one reason, Miss Douglas."

"What is that?"

"If I were to find my father, and if he were prepared to


own me, or were compelled to do so, I could repay Mrs.
Douglas in full."

"Oh, why are you always thinking of that? You must not
do so," she said. "You are stinting yourself and making your
life miserable, just for us. And it isn't right. Oh, it isn't
right!"

She was crying now; she could not help it. The thought
of his constant self-denial, the remembrance of the
hardships that he was bearing for their sakes, even though
the debt had never been his; the recollection of all this
touched her so deeply that she found it impossible to keep
back her tears.

"This letter alters everything," she said; "do think of


that. Even if you felt yourself bound to repay us when you
thought you were Mr. Fortescue's son, you cannot feel so
now. He was never your father except in name. Do
remember that, and do give up, once for all, the idea of
giving us that money back. The loss of it had nothing to do
with you, nor with any one at all belonging to you."

"I cannot look at it in that light, Miss Douglas," he said.


"If he was merely my father in name, still he was, at the
same time, the only father I have ever known. God helping
me, that debt shall be paid."

"Captain Fortescue."
"Yes, Miss Douglas."

"I'm afraid that letter is not of much use, after all."

"It may be," he said. "Who can tell?"

She sat looking into the fire for some minutes without
speaking, and then she said—

"I rather hope—" and then stopped.

"You rather hope what, Miss Douglas?"

"Oh, never mind. I did not mean to say it aloud. It was


only a foolish thought which had no business to come into
my mind."

"What was it?"

"Oh!" she said, laughing through her tears. "Such a silly


thing! I was going to say that I rather hoped you were not a
lord."

"Why not?"

"Oh, I don't know. I only thought we should not feel


that you were quite so much our friend. It was very foolish,
I know. Only you would seem so different to us then."

"Should I? I hope not," he said, gravely.

"And now I really must be going. What time is it,


Captain Fortescue?"

He looked at, his watch, and they found it was getting


late, so he got her coat, and she said good-bye to the old
landlady, and they set out for New Street. Then he went for
her ticket, and put her into the train, and just before it
started, he stepped into the carriage and sat down beside
her.

"Won't the train be off soon?" she asked. "Yes. I am


coming with you."

"Coming with me? Why?"

"I'm not going to allow you to walk alone along that


dark road from Deepfields Station at this time of night," he
said.

"Oh, I shall be quite all right; you really mustn't come.


You will be so tired, and it is not at all necessary. Please
don't come."

But he would take no refusal. There would be plenty of


time for him to catch the last train, he said, and Marjorie
felt sure that, when he had once made up his mind about
anything, there would be no possibility of moving him from
it.

They talked of the letter most of the way from the


station, and as they went through Daisy Bank she pointed
out the dark cottage where the still form of the old woman
was lying on the bed upstairs.

"How strange to think that my letter has been near you


all this time!" he said.

Then they got to Colwyn House, and at the gate, he


said good-bye. But before he left her he took her hand
between both his own, and said in a whisper, as he held it
for a moment—

"Thank you for all you have done for me to-day."


The next instant he was gone, and Marjorie let herself
in with her latchkey. She found that Mr. and Mrs. Holtby
were having supper. They wanted her to join them, but she
said she was tired, and would rather go to bed.

She fell asleep as soon as her head touched the pillow,


and she dreamt that his hands were still holding her own,
and she thought that she could still feel their pressure as he
said those words, which would ever remain in her memory
as long as life should last.

"Thank you for all you have done for me to-day."

CHAPTER XIX
GRANTLEY CASTLE

Two months after her visit to Birmingham, Marjorie was


standing on the platform at Daisy Bank, waiting for the
Wolverhampton train. How impatient she was to start!

How full of happiness was her face on that December


morning! For she was going home for Christmas. She could
hardly believe that it was only a year since she had seen
the dear home faces, and to have a whole month with them
all seemed almost too good to be true. Patty had come with
her to the station, and was full of regret at her departure,
full of promises to take her place in the holidays, and to do
all she could to keep the house tidy and clean.
As Marjorie looked at her, she could not help feeling
that the last few months had made Patty quite a different
girl. The brusqueness of her manner was gone; she was
more happy and more contented, and, in leaving her in
charge of the children and her mother, Marjorie felt that she
was leaving one who would tread, as far as possible, in her
footsteps; and as Patty would not have to go to school
during the time of her absence, she would be able to keep
all things as Marjorie had left them, and to save her mother
from having any extra work. Thus Marjorie was going home
with a happy heart, prepared to thoroughly enjoy her well-
earned holiday.

Perhaps our thoughts are never more busily occupied


than when we are travelling. As our bodies are being rapidly
carried over miles of distance, our thoughts wander further
still. As our eyes gaze out of the carriage window upon the
various scenes through which we are passing, the eyes of
our mind are gazing at other scenes, it may be in far-
distant lands. We see the views around us as if we saw
them not, for the inner pictures are so vivid that they
eclipse the outward ones. As we glance at our fellow-
passengers, ensconced with newspaper or book in the
corners of the carriage, we are looking, it may be, at other
faces and hearing other voices, far away from us in bodily
presence, but very near and constantly present to our inner
sight.

Marjorie's thoughts were very busy that cold wintry day.


Not only was she full of anticipation, picturing out to herself
the joy of arriving at home and seeing again the friends
from whom she had so long been parted; but at times, as
she travelled on, her thoughts, instead of flying northwards
far ahead of the train, travelled southwards, and found their
way to a little back sitting-room in a dingy street in
Birmingham.

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