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Research and Innovation, Position Paper 07 - 2011
Carbon Dioxide UtilizationElectrochemical Conversion of CO
2 Opportunities and Challenges
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Contact details:Narasi Sridhar [email protected]
Davion Hill [email protected]
Research andInnovation in
DNV
This isDNV
The objective o strategic researchis to enable long term innovationand business growth through newknowledge and services in supporto the overall strategy o DNV. Suchresearch is carried out in selectedareas that are believed to be oparticular signicance or DNV inthe uture. A Position Paper romDNV Research and Innovation
is intended to highlight ndingsrom our research programmes.
DNV is a global provider o servicesor managing risk. Establishedin 1864, DNV is an independentoundation with the purpose osaeguarding lie, property and theenvironment. DNV comprises 300oces in 100 countries with 9,000employees. Our vision is makinga global impact or a sae andsustainable uture.
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SummaryNature utilizes CO2 to produce myriad substances that are consumedby humans and animals. Some industrial processes aim to acceleratethe utilization o CO
2. There are essentially three pathways or utilizing
CO2: conversion o CO
2into uel, utilization o CO
2as a eedstock or
chemicals, and non-conversion use o CO2. The various utilization
technologies together have the potential to reduce CO2
emissions by
at least 3.7 gigatons/year (Gt/y) (approximately 10 % o total current
annual CO2
emissions), both directly and by reducing use o ossil uels.
However, much greater reductions are possible through wider adoption
o these technologies.
Biochemical or chemical conversion o CO2
to uels using biomass is an
attractive technology or converting large quantities o CO2
into readily
usable chemicals. Should only 5 % o liquid ossil uel be replaced
by biomass-based liquid uel, then, based on a range o liecycle CO2
emissions, a reduction o approximately 0.4 Gt/y o CO2would result. CO
2
conversion to minerals and insertion into polymers may have the benet
o sequestering CO2in relatively stable matrices. I 10 % o global building
material demand was met by conversion o CO2
to stable minerals, then a
potential reduction o 1.6 Gt/y o CO2
has been estimated. Chemical and
electrochemical conversion o CO2
into value-added chemical eedstock
and intermediates is attractive in terms o ossil uel avoidance. It is
estimated that the total CO2 emissions avoidance potential o this pathwayis about 0.3 Gt/y. The non-conversion uses o CO2, such as enhanced oil
recovery and solvent use, have the potential to consume about 1.4 Gt/y
o CO2.
There is no single, universally applicable pathway or CO2
utilization.
Depending on the industry, location, and other constraints, one
or more technologies may t better than others. An approach that
integrates dierent methods may be the most practical solution or many
applications. In this report, we present a small-scale demonstration o
an electrochemical technology or converting CO2
into ormic acid and
ormate salts. The technology appears to be promising, but several actorsmust be addressed to ensure commercial viability.
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CO2
can be utilized in three major pathways [1-3]: 1) as a
storage medium or renewable energy, 2) as a eedstock
or various chemicals, and 3) as a solvent or working fuid
(Figure 1). The use o CO2
to convert solar energy into
biomass and, rom there, to various renewable uels is now
widely supported by industry and governments as a means
to secure uture energy supplies and to decrease net CO2
emissions to atmosphere. While the use o ood crops, such
as corn, as a source or biomass uels will probably decrease
in the uture, second and third generation biouels that
are based on grasses and algae will increase in supply. It is
expected that, by 2050, biomass-based sources will supply
200 500 exajoules per year or about 50 % o the worlds
energy requirements [5]. It is anticipated that about 5 %
o the worlds liquid uel usage may arise rom biomass,
with a net CO2 reduction ranging rom 20 to over 100 %,
in comparison with conventional uels over their liecycles
[7].
Figure 1. Dierent pathways or utilizing CO2.
Pathways or Utilization o CO2
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It has been estimated that by 2035, the world will produce
15 Gt/y o CO2 rom burning liquid uels [6]. Thereore,
replacing about 5 % o liquid uels with biouel, and
assuming a 50 % liecycle reduction in CO2
emissions in
comparison with petroleum-based uel, has the potential
to reduce CO2
emissions by 0.4 Gt/y.
In addition to generating biomass, CO2 can be converted
via chemical and electrochemical processes to other
energy storage chemicals, such as syngas, ormic acid,
methane, ethylene, methanol, and dimethyl ether (DME)
[4]. Although it is more ecient to use the electricalenergy derived rom renewable power sources directly,
their variability poses a problem or many industries.
Furthermore, the distribution inrastructure or
hydrocarbon uel is well established. Finally, chemicals
such as ormic acid may be a useul storage medium
or hydrogen that could be used in uel cells or burned
directly.
An alternative pathway is to convert CO2 into chemical
eedstock. The entire portolio o commodity chemicals
are currently manuactured rom a ew primary buildingblocks or platorm chemicals in the ossil-based chemical
industry. CO2 can be used as a source material and,
utilizing renewable energy sources and water, can be
converted into a similar suite o building block chemicals.
Insertion o CO2 into epoxides to manuacture various
polymeric materials is an exciting technology as it not
only utilizes CO2, but also avoids using ossil eedstock
and creating CO2 emissions. It has been estimated that
the various chemical conversion pathways can consume
approximately 0.3 to 0.7 Gt/y o CO2 [8].
Conversion o CO2 into inorganic minerals that may be used
in building materials is being pursued by some companies
[9]. This involves a combination o electrochemical
reactions to generate the alkaline reactant and necessary
mineralization reactions. Initial estimates suggest that
even i 10 % o the worlds building materials were to be
replaced by such a source, consumption o 1.6Gt/y CO2
would result [8].
CO2 can also be used in various processes without rst
converting it into other chemical orms. The injection o
supercritical CO2 into depleted oil wells to enhance the
urther recovery o oil is well established. Indeed, this is
presently the only commercially viable technology orcarbon capture and storage (CCS). It has been estimated
that CO2 injection can increase oil recovery rom a
depleting well by about 10 to 20 % o the original oil in
place. Similarly, CO2 can be used to recover methane
rom unmined coal seams. It has been estimated that in
the U.S. alone, 89 billion barrels o oil could technically be
recovered using CO2, leading to a storage o 16 Gt o CO2
in the depleted oil reservoirs [10]. The use o supercritical
CO2 as a solvent in processing many chemicals (e.g., favor
extraction) is also well established. New uses o supercritical
CO2 in chemical processing are emerging, and have theadded benet o reducing water usage. Supercritical CO2
is also being explored as a heat transer fuid or some
geothermal applications. These non-conversion methods
o utilization constitute a signicant raction o the total
CO2 emissions.
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Although there are many pathways or CO2 utilization, this
position paper details DNVs eorts in electrochemical
reduction o CO2. The electrochemical method has
several advantages:
1. Extensive research during the last several decades
has yielded high selectivity, low cost, heterogeneous
catalysts or CO2 electrochemical reduction to
various useul products or aqueous reaction systems
[11-27].
2. Electrochemical conversion can be perormed at
room temperature and ambient pressure.3. I the supporting electrolytes are ully recycled and
the anode reactions can be perormed using waste
water, then the overall chemical consumption can be
minimized to just water or wastewater.
4. A renewable source o electricity can be used to drive
the process, including solar, wind, hydroelectric,
geothermal, tidal, and thermoelectric processes.
Thereore this method can also be used as a
renewable electricity storage mechanism; it converts
the electrical energy to chemical energy by producing
uels rom CO2, such as methanol and ormic acid.The stored energy can be released later or end-
use by oxidization o the uels through uel cells or
normal uel-burning engines.
5. Electrochemical conversion can be augmented using
light energy or solar thermal energy.
6. The electrochemical reaction system is modular and
thus scale-up is relatively simple.
7. In general, the electrochemical systems have a
compact design.
Using metal or alloy electrodes/catalysts, various products
can be produced by electrochemical reduction o CO2,
including carbon monoxide (CO), ormic acid (HCOOH),
oxalates (C2O4-), hydrocarbons (e.g., ethylene C2H4),
and alcohols (e.g., methanol, CH3OH). DNV selected
the Electrochemical Reduction o CO2 to Formate/
Formic Acid (ECFORM) as the process or comprehensive
evaluation o the technical easibility or CO2 utilization
because commercialization o this process was considered
to be most likely to be protable.
As mentioned previously, ormic acid can be a useul
storage medium or hydrogen that could be used in uel
cells or burned directly. As shown in Figure 4, the energy
density o ormic acid, via its use in a ormic acid uel cell, isquite attractive in comparison with other storage methods.
The recoverable energy density that would be available via
the combustion o methanol, ethylene, or methane, or the
use o ormic acid in uel cells, is higher than conventional
energy storage technologies, as shown in Figure 2. Note
that the vertical axis is log scale.
Figure 2. Products created rom electrochemical CO2 conversionprocesses have signifcantly more energy density than other energy
storage technologies.
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Formic acid and carbon monoxide require little energy
or their respective market value, as shown in Figure 4.
Methanol is another attractive uel, but requires more
electrical energy than ormic acid or its production rom
CO2. Ethylene and methane require signicantly more
energy input, and the methane market price is constrained
by natural gas prices.
Both ormic acid and carbon monoxide sell or near
$1,200 per ton o product and require approximately 2500
kWh/ton or their production via electrochemical CO2
conversion. These prices are likely to decrease as their
production volume increases, and their usage may also
increase as their price decreases. Other products, such as
methane, require nearly 40,000 kWh/ton or conversion,
and would only achieve $200-$300 per ton on the market.
Carbon monoxide is dicult to store and transport, and
thereore ormic acid is a more practical and desirable
product.
The current world market demand or ormic acid and
ormate salts is quite low (several million metric tons). The
traditional uses o ormic acid have been in the leather
tanning industry and animal eed markets. However, new
uses, in terms o hydrogen storage and uel cells, are being
developed by BASF and others, making this an attractive
chemical. Formate salts are used in oil well completion
and in de-icing o airport runways. Larger volumes and
somewhat lower prices may expand these, and other,
applications.
Figure 3. Formic acid and carbon monoxide have higher value rom
the energy required or their creation than conventional uels such asmethanol or methane.
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The ECFORM Process
A schematic diagram o the ECFORM process is shown
in Figure 4. It consists o two electrodes, the cathode
(negative electrode) and the anode (positive electrode),
across which an electrical voltage is applied. The two
electrodes are placed in two dierent chambers, separated
rom each other by an ion exchange membrane. This
prevents bulk mixing o the solutions fowing in each o
the chambers, while simultaneously allowing ions to move
across the membrane and maintain electrical continuity. A
suitable electrolyte is introduced into the cathode chamber
along with CO2. The electrolyte comes into contact with
the cathode, and the dissolved CO2 is electrochemicallyreduced to the desired products. This electrical circuit
is completed by the complementary oxidation reaction
occurring in the anode chamber. In ECFORM, tin or
proprietary tin-based alloys are used as the cathodes that
convert CO2
to ormate salts. Small concentrations o by-
products (hydrogen and CO) are also produced at the
cathode. An oxygen evolution reaction takes place at the
anode.
An important metric o the process is the energy
consumption, which is determined by the number oelectrons (n) involved in reducing 1 molecule o CO
2to
products, cell voltage, and the current eciency, also called
Faraday eciency (FE). The FE denotes the percentage o
the total current used or the desired product (i.e., the
selectivity). The calculations in Figure 5 include additional
energy consumed by auxiliary components, such as pumps.
As shown in Figure 5, the reduction o CO2
to ormate/
ormic acid and to carbon monoxide, respectively, appears
to be the best option or practical development or at least
two reasons. First, both reactions involve the participation
o only two electrons, and thereore the electrical power
consumption is the lowest. Secondly, the high FE o CO
and ormate/ormic acid reactions have been achieved onaordable metal cathodes, urther minimizing the energy
consumption and cost. The next promising reaction may
be the production o methanol. Although this involves 6
electrons or each molecule o methanol ormed, the low
over potentials on the catalysts reduce the cell potential
to nearly hal o that or other electrochemical processes.
Thus, relatively lower specic energy consumption can
also be achieved.
An economically viable electrochemical technology
requires optimization o our key parameters (Figure 6):high current densities, high FE, low specic electricity
consumption, and long electrode lietime. The minimum
Figure 4. A schematic representation o the ECFORM process to convert CO2
to ormate/ormic acid.
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values or each parameter in a commercially viable
electrochemical process are also included in Figure 6,along with target areas or improvements. In addition,
there are other important requirements, such as high one-
pass conversion rate and continuous operation.
In general, higher current densities result in lower FE and
shorter lietimes because o competing reactions. With
longer run times, FE tends to decrease (catalyst/cathode
degradation) and cell voltage increase, both o which
result in greater power consumption. DNV has developed
novel cathode and anode catalysts that reduce the total
cell voltage by almost 1 volt [26, 27]. Additionally, DNV
has designed a reactor that reduces the resistive losses
by another 2 volts, thus resulting in an overall decrease
in the total cell voltage by about 60 %, compared withthe data published in the literature [27]. Furthermore,
the long-term perormance o the cathode catalyst has
been increased by at least 20 times over that reported in
the literature. This has mainly been achieved through
improvements in the electrochemical cell design and
operational parameters. Fundamental studies perormed
by The Ohio State University, in collaboration with DNV,
have improved our understanding o the cathode catalyst
degradation mechanisms. This will enable urther
advances in catalyst lie. DNV has also identied less
corrosive electrolytes that will reduce both capital and
operational expenditure.
Figure 5. Specifc energy consumption vs. Faradaic efciency (FE)
or various products. The thicker lines with data points indicate
experimental results achieved in various studies.
Figure 6. The relationship among the key parameters in ERC processes.
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ECFORM Reactor Demonstration
Testing o a lter-press type, bench-scale reactor indicated
a set o conditions or most avorable selectivity and
reactivity or ormate production. Figure 7 shows an
example in which, under optimum pressure and fow rate
control, the selectivity (FE) o a High Surace Area (HSA)
cathode is kept constant over a range o applied potentials
or one day. Since large electrodes have a tendency to
display potential variation, this analysis indicates that
slight changes in electrode potential will not aect the
productivity o ECFORM, once process parameters are
controlled.
Long-term stable perormance o HSA electrodes was
determined by periodic measurement o reactivity
(current density) and selectivity (FE rom ormate product
measurement in catholyte samples) under constant
optimum operation. The results in Figure 8 indicate stable
perormance over 4 days, with no appreciable damage or
degradation o the tin electrodeposited carbon electrode.
This is a signicant improvement over results reported in
the literature. These results suggest that electrochemical
conversion o CO2may be a commercially viable technology
in the uture.
A semi-pilot size reactor with a supercial area o 600 cm2
(capable o reducing approximately 1 Kg/d o CO2) was
built and assembled, with other process components and
instruments, into a solar-powered trailer to demonstrate
the operation o the process using completely renewable
power (Figure 9). The demonstration reactor serves
several purposes. Firstly, it showcases the capability
o the ECFORM process to utilize renewable energy,
such as solar, to convert CO2 into a commercially useulproduct. Secondly, the reactor system can be used to test
and improve the process, in terms o the hydrodynamics,
heterogeneity o the suraces, and eects on selectivity,
automation, and controls, saety, and the overall eciency
o the system. Finally, the demonstration reactor provides
a useul means by which process and value chain analysis
models can be validated. The reactor has been modeled
using a model-based fow sheet simulator, gPROMS, and
this model will also be used or scale-up assessments.
Figure 7. Near constant FE over a potential
range (-1.4 to -2.3 Vsce) o a HSA cathodeunder optimum operating conditions.
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Figure 8. HSA electrodes displayed
constant reactivity and selectivityover 4 days.
Figure 9. Demonstration reactor
assembled in a solar-powered trailer.
Solar PanelECFORMSetup
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Analysis o the CO2
utilization processes can be conducted
in terms o cradle-to-grave CO2
emission (liecycle analysis
or LCA) or a source-to-gate analysis, in which the boundaries
start with the source o CO2
and end with the product that
is delivered by a given process. The latter analysis, reerred
to here as value chain analysis (VCA) is convenient or
understanding the net CO2
emitted in a given utilization
process, since the product delivered is no dierent rom
that made by utilizing ossil uel. Most importantly (and
unlike LCA), VCA also computes the net present value
o the process. Thus, VCA provides an opportunity or
comparing any new process with conventional processes,as well as indicating uture developmental work that could
be targeted in an economically meaningul way. The VCA
model that we developed or the ECFORM process can
be readily modied or analysis o other CO2
utilization
processes.
Most CO2utilization processes require mixed gas collection
rom the emissions source. I the exhaust source contains
additional gases (such as nitrogen, sulur, or nitrogen
oxides), some additional purication or capture o the
CO2 will be needed. The delivery o the mixed exhaustgas to the capture stage, and the capture process itsel,
requires inputs o energy and/or consumables, and these
must be included in the total VCA. Once the puried CO2
has been diverted to the conversion process, this delivery
may also require urther energy inputs. Finally, the
conversion process itsel will have energy and consumables
inputs. The entire value chain can be compared with
direct emissions (with or without nes), carbon capture
and storage (CCS), or with conventional processes or
manuacturing the same product. Multiple scenarios
can be computed, and these can include carbon taxes (i
any), energy costs, consumables, and the value o the nal
product, such that the total impact o these actors on the
protability and net present value o the investment into
the CO2 conversion process can be assessed.
Emissions source and gas delivery
DNV has analyzed emissions scenarios and sources,
ranging rom the size and scale o a coal-red power plantto point sources within a petrochemical renery. The
electrochemical CO2
conversion process has been tested
via the model and demonstrates the greatest probability o
protability occurs when the ollowing conditions are met:
- the CO2
is delivered in pure or mostly-pure orm;
- process heat or other renewable energy orms are
available;
- process volumes are manageable (
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When the above conditions are met, the protability,
energy balance, and carbon balance o the CO2conversion
process become most sensitive to the parameters o the
conversion process itsel.
CO2
Separation, Capture, and Delivery
Because o the conditions described previously, the
separation, capture, and delivery o CO2
to the conversion
process are considered separately and independently rom
the CO2
conversion process. The availability o already
captured or puried CO2
will aect the protability o the
process. The energy penalty or a coal plant capturing CO2
(not including transport and storage) ranges rom 0.2 to
0.35 MWh/t o CO2
captured. This represents about 5 to
10 % o the energy required or conversion on a kWh/ton
basis, as ECFORM requires approximately 2.5 to 4 MWh/
ton o converted CO2. The dierence between ECFORM
and the CCS process is that whereas ECFORM produces
a useul product, CCS does not. Thereore ECFORM is
an energy conversion process. There are other possible
CO2 separation and sequestration technologies that couldlower these energy requirements.
CO2
Conversion
Based on dierent chemical reaction routes, the
protability o the CO2
conversion process depends not
only on the value o the nal products, but also on the
energy and consumables that are required to support
the electrochemical reaction. As shown in Figure 11,
i the process requires additional chemicals, such as
sodium hydroxide and hydrochloric acid, to support the
reactions, then the net present value o the reaction is
largely negatively driven by these consumables, on top o
the already substantial energy demands.
Figure 11. Reaction pathways that are heavily dependent on
consumables drive the proftability o the reaction in the negative
direction, more so than by the energy costs.
Figure 12. Reaction pathways that minimize consumables become moredominated by energy, which must be eectively managed.
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However, i the use o consumable chemicals is decreased,
or example through the use o electrolyte recovery
processes and the utilization o alkaline waste water, thenenergy demands dominate the overall process economics
(Figure 12). While the energy costs are increased, the
reaction is more sustainable i renewable energy is used
or the process.
As is shown in Figure 13, the prot margins can be
increased as energy costs are reduced. There is potential
or additional revenues in utilizing the load leveling
needs o the electric grid. These opportunities are called
responsive ancillary services. For example, i energy-
intensive processes such as ECFORM are used to regulate
voltage rom a wind energy acility, the processes gain
additional revenues while being renewably powered.
Additionally, revenues rom carbon credits or avoidance
o carbon tax may also aid in protability. In this analysis, a
carbon credit revenue o up to $50/ton does not alter theprotability substantially, but the combined revenues rom
carbon credits and energy management reduce the energy
costs by 15 %.
Four Scenarios or CO2
Conversion
Four possible scenarios are envisioned or assessing the
protability o an electrochemical conversion process.
This assessment does not consider capital expenditures
or the time value o money. Also, the cost o consumables
is considered to be negligible in comparison with energy
costs. Finally, it is assumed that the ormic acid resulting
rom the electrochemical process does not need urther
concentration, or example through distillation or
Figure 13. Value-added process improvements decrease the energy
costs o the ECFORM process.
Figure 14. The dierence between sales price and operational cost or
ECFORM process (red numbers) under dierent scenarios (only energy
costs are included consumable costs are considered to be negligible).
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evaporation. The X-axis represents the price o the
product made in the ECFORM process. This depends on
many actors, including the volume manuactured and
market demands. The Y-axis represents the CO2
price,
either through a trading scheme or a tax. The numbers
represent dierent values o protability (assumed as a
simple dierence between expected value o price minus
cost) or the dierent scenarios. The cost is calculated
assuming an energy consumption o 3859 kW/ton ormic
acid. Electricity prices are assumed to range rom $0.07/
kWh to $0.15/kWh, with a peak requency at $0.10/kWh.
The energy cost thereore ranges rom $270 to $578 per
ton o ormic acid, with an average o $420 per ton o
ormic acid. For example, i the price o ormic acid is
assumed to be $1220/ton and the price o CO2
is $200/
ton o CO2
(1 ton o ormic acid reduces CO2
by almost 1
ton), then operational prot is $1200+$200-$420 = $980
per ton. Our analyses indicate that the simple margins
(price minus the cost o manuacturing) are benecial or
this process under the scenarios considered.
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CO2
utilization is being increasingly recognized as a
method by which global CO2
emissions can be reduced
in an economical manner. This is especially true or
industries, such as reneries, which cannot implement
CCS economically.
Considerable research is being conducted in many
directions to urther the economic viability o processes
that utilize CO2. Biomass conversion to uels is perhaps
the most intensively pursued route, not only to mitigate
CO2
emissions, but also to secure alternative uel supply.
Conversion o cellulosic biomass into alcohols and algaeinto biodiesel or other hydrocarbon uel is predicted
to become extensively adopted in the coming decade.
Liecycle assessments o these uel sources demonstrate
considerable reductions in CO2
emissions compared with
petroleum uels. However, their present economic viability
is dependent on government subsidies.
Several companies are pursuing thermochemical
conversion o CO2
into chemical eedstock or polymers.
Research and development are currently ocused towards
reducing the temperature o conversion, increasing catalystlie, and decreasing the use o consumables. Conversion o
CO2
into minerals has advanced signicantly, with at least
one company claiming commercial viability or large-scale
deployment. Carbon policies that impose a signicant
increase in carbon prices are necessary to sustain these
eorts until they can become economically viable.
Electrochemical and photoelectrochemical conversion
routes will come to the ore in the next decade. Current
research is yielding catalysts with long-term perormance
characteristics and low energy use, but signicant
technical advances are still needed or large-scale use.
Electrochemical conversion promises to be deployable in
many systems, because o its low ootprint, its scalability, its
ungible use o electricity, and its ability to produce many
end products. The combination o the electrochemical
process with grid-based ancillary services can make these
processes economically viable, even without a carbon
tax. DNV will continue its eorts in improving the
ECFORM technology, particularly making it more robust
and economically viable, and explore opportunities
or customizing CO2
utilization methods or industrial
applications.
All these technologies will rely on ecient carbon capture,as many industrial sources produce dispersed and dilute
efuents containing CO2.
Just as integrated bioreneries have come to characterize
the use o multiple technologies to make an array o
products rom biomass, multiple technologies or utilizing
CO2
in interconnected systems, tailored to a given
application, may be the path ahead or uture sustainable
management o CO2.
The uture
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Reerences
General Reading
1. M.M. Halmann, Chemical xation o carbon dioxide, Methods or
recycling CO2
into useul products, CRC Press, 1993.
2. M.M. Halmann and M. Steinberg, Greenhouse Gas Carbon Dioxide
Mitigation: Science and Technology, CRC Press, 1998
3. M. Aresta (Editor), Carbon Dioxide as a Chemical Feedstock, Wiley-
VCH, 2010.
4. G.A.Olah, A.Goeppert, and G.K.Surya Prakash, Beyond Oil and Gas:
The Methanol Economy, Wiley-VCH, 2009.
Specifc Reerences
5. Bioenergy A sustainable and reliable energy source, A review
o status and prospects, IEA Bioenergy: Exco 2009:05, www.
ieabioenergy.com.6. Increasing Feedstock Production or Biouels, Biomass Research and
Development Board (U.S.), 2009.
7. International Energy Outlook 2010, U.S. Energy Inormation
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