The_Catalyst_Review_June_2023 - 12

SPECIAL FEATURE
Process Integration and Approaches
The International Energy Outlook (IEO) estimates that Industry uses 54% of the world's available energy. The estimated growth in global
industrial energy consumption from 222 quadrillion British thermal units (BTU) in 2012 to 309 quadrillion BTU in 2040 is 1.2% annually
on average. Implementing and expanding electricity transmission and distribution networks, new process heating technologies, and the
necessary infrastructure to support hydrogen production through water electrolysis are all necessary steps for industry electrification.
However, certain difficulties and obstacles must be overcome to achieve this goal. For example, there are currently no policies for
achieving electrification, although several nations are beginning to enact measures to accomplish a large-scale green revolution. In
addition, Industry has historically been hesitant to adapt, especially when replacing outdated technology and changing established
business structures and best practices. Industrial sectors are remarkably diverse, and it is challenging to reduce energy costs in areas
where there is demand for high-temperature heat or energy (for example, in the production of cement, iron and steel, and glass). For
the chemical industry, which demands a high capacity and high availability (>90%), together with a competitive cost of production, the
availability of intermittent renewable electricity could be very costly.
Selected Applications
One industrial process that has recently
experienced rapid growth is the manufacture
of hydrogen. The production of H2
at a 10% annual pace. H2
can significantly
impact power systems, transportation, and the
use of extra electricity from renewable energy
sources. Currently, the Haber-Bosch process
produces 60% of the world's H2
supply, with
the other 40% going to refineries and other
chemical companies. Hydrocarbons are the
primary sources of H2
generation, with coal and
water electrolysis as secondary sources (Figure
4). Due to the high energy requirements, the
cost of producing H2
using water electrolysis is
substantially higher than the cost of producing
H2
However, reforming and gasification can be
employed to create H2
through the reforming of hydrocarbons.
from fossil fuels.
Electrified chemical processes differ significantly
from traditional fossil-fuel-based industries. To
begin with, feedstocks for chemical conversion
(e.g., H2
, CO2) will necessitate energy-intensive
transformation, which will account for a significant
Figure 4. The route for power-to-X (PtX) scheme. Source: Wahyono et al., 2020
portion of total power consumption. As conversion methods evolve, most utilities will get power through heat pumps or electrically
heated furnaces. The availability of carbon-neutral power at a fair price is thus critical for deploying low-carbon and sustainable chemical
processes via electrification and avoiding a cost explosion. In this regard, comparing various processes will require the development of
new techniques and critical performance indicators.
Conclusions
Disruptive catalysts will play a critical role in using renewable energy sources to drive chemical transformation. Such transformations will
take place either directly using electrons or photons or indirectly using renewable electrical energy to create a plasma-catalysis synergy
to control the pathways of transformation. Using electrochemistry to react carbon dioxide, nitrogen, and water with renewable sources
can yield the commodity chemicals needed for automated and additive manufacturing processes, which are fully integrated with the
energy and industrial system. Such a transformation represents a new business model for industrial players, prompting them to produce
commodities or specialty/fine chemicals they would not have otherwise considered.
Creating a large-scale electrified chemical industry presents challenges primarily associated with cost, infrastructure, policy and
regulation, and industrial adaptability. Globally, end-user electricity consumption is increasing rapidly, industries are still heavily
dependent on fossil fuel-based electricity, and most energy-intensive processes require heat. Despite this, there is growing consensus
to shift to more sustainable processes quickly. The impact of such a transformation on a world-scale economy is not fully understood.
Implementing innovative technologies will require a significant effort from industries and governments to generate awareness from an
economic, environmental, and social perspective.
12
The Catalyst Review
June 2023
is growing

The_Catalyst_Review_June_2023

Table of Contents for the Digital Edition of The_Catalyst_Review_June_2023