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Search Results (266)

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Keywords = methane to methanol

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12 pages, 3743 KB  
Communication
Atomistic Blueprinting of Electrochemical CO Reduction Reaction Pathways over Transition Metal Phosphides
by Muhammad Awais and Younes Abghoui
Molecules 2026, 31(8), 1334; https://doi.org/10.3390/molecules31081334 - 18 Apr 2026
Viewed by 134
Abstract
Ecosystem disruption is a significant challenge of the contemporary age, arising from substantial CO2/CO emissions resulting from dependence on fossil fuels as a primary energy source. Scholars across several fields are striving to mitigate these severe greenhouse gas emissions. The most [...] Read more.
Ecosystem disruption is a significant challenge of the contemporary age, arising from substantial CO2/CO emissions resulting from dependence on fossil fuels as a primary energy source. Scholars across several fields are striving to mitigate these severe greenhouse gas emissions. The most promising method is to adsorb carbon and convert it into sustainable energy. We sought to diminish CO levels by electrocatalytic reduction using innovative catalytic surfaces, namely transition metal phosphides (TMPs). During this work, VP is recognized as a very effective surface for CO reduction and the synthesis of formaldehyde, methanol, and methane at −0.68 V. Further, hydrogen evolution reaction (HER) does not pose a challenge for any surface, despite all TMPs facilitating CO reduction. In summary, predictions derived from this density functional theory (DFT)-guided analysis provide experimentalists with insights to validate experiments and synthesize active catalysts for CO conversion and green energy generation. Full article
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37 pages, 1591 KB  
Review
Methane Pyrolysis for Low-Carbon Syngas and Methanol: Economic Viability and Market Constraints
by Tagwa Musa, Razan Khawaja, Luc Vechot and Nimir Elbashir
Gases 2026, 6(2), 18; https://doi.org/10.3390/gases6020018 - 2 Apr 2026
Viewed by 484
Abstract
As the global imperative for climate neutrality intensifies, hydrogen (H2) from fossil fuels remains central to decarbonizing hard-to-abate sectors. Conventional production via steam methane reforming (SMR), however, is carbon-intensive and, even with carbon capture and storage (CCS), incurs energy penalties and [...] Read more.
As the global imperative for climate neutrality intensifies, hydrogen (H2) from fossil fuels remains central to decarbonizing hard-to-abate sectors. Conventional production via steam methane reforming (SMR), however, is carbon-intensive and, even with carbon capture and storage (CCS), incurs energy penalties and long-term storage constraints. This review develops a harmonized well-to-gate, market-oriented framework to evaluate methane pyrolysis (MP) relative to SMR and autothermal reforming (ATR), with or without CCS, moving beyond reactor-focused assessments toward system-level commercialization analysis. MP decomposes methane into hydrogen and solid carbon, avoiding direct CO2 formation and the need for CCS infrastructure. Integrating with the reverse water–gas shift (RWGS) reaction enables flexible syngas production with adjustable H2:CO ratios for methanol and chemical synthesis. A central finding is the dominant role of the “carbon lever”: MP generates approximately 3 kg of solid carbon per kg of H2, making the carbon market’s absorptive capacity the primary scalability constraint. While carbon monetization can reduce levelized hydrogen costs, large-scale deployment would rapidly saturate existing carbon black and specialty carbon markets. Techno-economic evidence indicates that carbon prices above $500/ton are required to achieve parity with gray hydrogen, whereas $150–200/ton enables competitiveness with blue hydrogen. Lifecycle assessments further show that climate superiority over SMR or ATR with CCS requires upstream methane leakage below 0.5% and very low-carbon electricity. Commercial readiness varies, with plasma MP at TRL 8–9 and thermal, catalytic, and molten-media pathways remaining at the pilot or demonstration stage. Parametric decision-space analysis under harmonized boundary assumptions shows that MP is not a universal substitute for reforming but a conditional pathway competitive only under aligned conditions of low-leakage gas supply, low-carbon electricity, credible carbon monetization, and supportive policy incentives. The review concludes with a roadmap that highlights standardized carbon certification, end-of-life accounting, and long-duration operational data as priorities for commercialization. Full article
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30 pages, 1888 KB  
Review
Direct Chemical Conversion of Methane into Acetic Acid
by Eun Duck Park
Catalysts 2026, 16(4), 310; https://doi.org/10.3390/catal16040310 - 1 Apr 2026
Viewed by 444
Abstract
Methane, as an abundant and relatively clean resource, has primarily been converted into various chemical products via indirect conversion through synthesis gas, a mixture of CO and H2. Recently, interest in direct methane conversion technologies with lower energy consumption has increased. [...] Read more.
Methane, as an abundant and relatively clean resource, has primarily been converted into various chemical products via indirect conversion through synthesis gas, a mixture of CO and H2. Recently, interest in direct methane conversion technologies with lower energy consumption has increased. Compared to research on methanol production via selective oxidation of methane, studies on the direct conversion of methane to acetic acid have been relatively scarce, but significant research progress has been made recently. This review classifies reports on the direct conversion of methane into acetic acid according to catalyst type (homogeneous vs. heterogeneous catalysts) and reaction conditions, and discusses the advantages and disadvantages of each approach. A relatively high yield of acetic acid can be achieved using CO as a carbonylating agent. However, the direct conversion of methane and CO2 into acetic acid is more attractive from an environmental perspective. Recent advances in the field of electrocatalysis for this purpose are noteworthy. Other non-thermal catalytic methods, including photocatalysis, photoelectrocatalysis, and plasma processes, are also included. Based on the current state-of-the-art research trends in this field, future research directions are proposed. Full article
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23 pages, 2024 KB  
Article
Limitation of Power-to-Methanol: Identifying the Barriers of Bridging Energy and Bio-Carbon to Produce Decentralized Renewable Methanol via Integrated Economical and Environmental Evaluation
by Hans Gelten, Kim Hemmer, Benno Aalderink, Richard van Leeuwen and Zohre Kurt
Energies 2026, 19(7), 1626; https://doi.org/10.3390/en19071626 - 25 Mar 2026
Viewed by 543
Abstract
Power-to-X technologies play a crucial role in accelerating the energy and material transition. A key opportunity lies in integrating these systems with existing bio-based infrastructures such as anaerobic digesters, providing a reliable source of biogenic carbon. Developing effective Power-to-Methanol (PtM) pathways requires a [...] Read more.
Power-to-X technologies play a crucial role in accelerating the energy and material transition. A key opportunity lies in integrating these systems with existing bio-based infrastructures such as anaerobic digesters, providing a reliable source of biogenic carbon. Developing effective Power-to-Methanol (PtM) pathways requires a comprehensive understanding of process behavior through detailed simulation, including technical performance, economic feasibility, and environmental consequences. Despite growing interest, substantial variation remains in published levelized methanol costs, and many assessments insufficiently account for the full environmental footprint of production routes. This study evaluates the potential of PtM deployment in the Netherlands by comparing two pathways that utilize biogenic carbon sources: (i) hydrogenation of captured CO2 using green hydrogen and (ii) dry methane reforming (DMR) of biogas, followed by catalytic syngas conversion to methanol. Results indicate that operational expenses—mainly driven by renewable electricity consumption—far outweigh capital investment. Both routes yield an LCoMeOH of approximately €2630 per tonne, about five times the cost of fossil-based methanol. Life cycle analysis shows that DMR performs more favorably overall, although elevated freshwater ecotoxicity and eutrophication result from digestate application as fertilizer. Continued improvements in renewable energy integration and nutrient recovery technologies are essential for enhancing future economic and environmental performance. Full article
(This article belongs to the Special Issue 11th International Conference on Smart Energy Systems (SESAAU2025))
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55 pages, 13041 KB  
Review
Application, Challenges and Perspectives of Catalysts Applied in Power-to-X Technology to Produce Hydrogen-Derived Vectors for Energy Transition
by María Lorena Malagón-Quinto, Hilda Elizabeth Reynel-Ávila, Didilia Ileana Mendoza-Castillo, Adrián Bonilla-Petriciolet, Norma Aurea Rangel-Vázquez, Gloria Sandoval-Flores and Sarah Essam
ChemEngineering 2026, 10(3), 40; https://doi.org/10.3390/chemengineering10030040 - 12 Mar 2026
Viewed by 978
Abstract
This review analyzes the catalytic routes for the Power-to-X (PtX) conversion of hydrogen to methane, methanol, ammonia, formic acid, and synthetic hydrocarbon fuels. The key reactive synthesis technologies and catalysts for each vector are described. Recent studies and pilot projects summarizing the reaction [...] Read more.
This review analyzes the catalytic routes for the Power-to-X (PtX) conversion of hydrogen to methane, methanol, ammonia, formic acid, and synthetic hydrocarbon fuels. The key reactive synthesis technologies and catalysts for each vector are described. Recent studies and pilot projects summarizing the reaction pathways of each vector and the associated catalyst technologies are also discussed. The analysis indicates that catalyst selection critically influences the efficiency and selectivity of these reactive systems. Some catalyst synthesis routes rely on expensive critical minerals (e.g., Ru and Rh), which raise technical and economic challenges for their industrial application. Catalyst deactivation and scale-up limitations are also relevant issues to be resolved. Emerging catalysts (e.g., Fe–Co or Co–Ni bimetallics, core–shell materials, metal-organic frameworks (MOFs), electrides, covalent-organic frameworks (COFs), and perovskites) are being explored to enhance stability, selectivity, and deactivation. Europe leads PtX development to consolidate the industrial production of hydrogen-based vectors with strong policy support, while the industrial initiatives in Latin America are limited (for instance, Chile’s green methanol and ammonia projects are examples) despite its great potential to generate renewable energy. In summary, Power-to-X can store renewable energy and close the carbon loop; however, its industrial consolidation demands catalyst innovation and supportive regulatory frameworks to overcome the challenges highlighted in this review. Full article
(This article belongs to the Special Issue Advances in Renewable Energy Derivatives)
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35 pages, 2952 KB  
Review
Thermo-Catalytic Carbon Dioxide Hydrogenation to Ethanol
by Xianyu Meng, Ying Wang, Jie Li, Hongxing Wang, Chenglong Yu, Jia Guo, Zhuo Zhang, Qingli Qian and Buxing Han
Chemistry 2026, 8(2), 14; https://doi.org/10.3390/chemistry8020014 - 28 Jan 2026
Cited by 1 | Viewed by 1510
Abstract
The catalytic hydrogenation of carbon dioxide (CO2) represents a transformative approach for reducing greenhouse gas emissions while producing sustainable fuels and chemicals, with ethanol being particularly promising due to its compatibility with existing energy infrastructure. Despite significant progress in converting CO [...] Read more.
The catalytic hydrogenation of carbon dioxide (CO2) represents a transformative approach for reducing greenhouse gas emissions while producing sustainable fuels and chemicals, with ethanol being particularly promising due to its compatibility with existing energy infrastructure. Despite significant progress in converting CO2 to C1 products (e.g., methane, methanol), selective synthesis of C2+ compounds like ethanol remains challenging because of competing reaction pathways and byproduct formation. Recent advances in thermo-catalytic CO2 hydrogenation have explored diverse catalyst systems including noble metals (Rh, Pd, Au, Ir, Pt) and non-noble metals (Co, Cu, Fe), supported on zeolites, metal oxides, perovskites, silica, metal–organic frameworks, and carbon-based materials. These studies reveal that catalytic performance hinges on the synergistic effects of multimetallic sites, tailored support properties and controlled reaction micro-environments to optimize CO2 activation, controlled hydrogenation and C−C coupling. Mechanistic insights highlight the critical balance between CO2 reduction steps and selective C−C bond formation, supported by thermodynamic analysis, advanced characterization techniques and theoretical calculations. However, challenges persist, such as low ethanol yields and undesired byproducts, necessitating innovative catalyst designs and optimized reactor configurations. Future efforts must integrate computational modeling, in situ/operando studies, and renewable hydrogen sources to advance scalable and economically viable processes. This review consolidates key findings, proposes potential reaction mechanisms, and outlines strategies for designing high-efficiency catalysts, ultimately providing reference for industrial application of CO2-to-ethanol technologies. Full article
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34 pages, 7114 KB  
Article
CFD Analysis of Equivalence Ratio Effects on Combustion and Emissions in a Methanol–Diesel Dual-Fuel Marine Engine
by Van Chien Pham, Van Vang Le, Jae-Hyuk Choi and Won-Ju Lee
Energies 2026, 19(3), 626; https://doi.org/10.3390/en19030626 - 25 Jan 2026
Cited by 1 | Viewed by 645
Abstract
Methanol is a promising alternative marine fuel due to its favorable combustion characteristics and potential to reduce exhaust emissions under increasingly stringent International Maritime Organization (IMO) regulations. This study presents a three-dimensional computational fluid dynamics (CFD) analysis of a four-stroke, medium-speed marine engine [...] Read more.
Methanol is a promising alternative marine fuel due to its favorable combustion characteristics and potential to reduce exhaust emissions under increasingly stringent International Maritime Organization (IMO) regulations. This study presents a three-dimensional computational fluid dynamics (CFD) analysis of a four-stroke, medium-speed marine engine operating in methanol–diesel dual-fuel (DF) mode. Simulations were performed using AVL FIRE for a MAN B&W 6H35DF engine, covering the in-cylinder process from intake valve closing to exhaust valve opening. Nine operating cases were investigated, including seven methanol–diesel DF cases with equivalence ratios (Φ) from 0.18 to 0.30, one methane–diesel DF case (Φ = 0.22), and one pure diesel baseline. A power-matched condition (IMEP ≈ 20 bar) enabled consistent comparison among fueling strategies. The results show that methanol–diesel DF operation reduces peak in-cylinder pressure, heat-release rate, turbulent kinetic energy, and wall heat losses compared with diesel operation. At low to moderate Φ, methanol DF combustion significantly suppresses nitric oxide (NO), soot, and carbon monoxide (CO emissions), while carbon dioxide (CO2) emissions increase with Φ and approach diesel levels under power-matched conditions. These results highlight methanol’s potential as a viable low-carbon fuel for marine engines. Full article
(This article belongs to the Section I2: Energy and Combustion Science)
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27 pages, 10006 KB  
Article
Analysis About the Leaks and Explosions of Alternative Fuels
by José Miguel Mahía-Prados, Ignacio Arias-Fernández, Manuel Romero Gómez and Sandrina Pereira
Energies 2026, 19(2), 514; https://doi.org/10.3390/en19020514 - 20 Jan 2026
Viewed by 510
Abstract
The maritime sector is under growing pressure to decarbonize, driving the adoption of alternative fuels such as methane, methanol, ammonia, and hydrogen. This study evaluates their thermal behavior and associated risks using Engineering Equation Solve software for heat transfer modeling and Areal Locations [...] Read more.
The maritime sector is under growing pressure to decarbonize, driving the adoption of alternative fuels such as methane, methanol, ammonia, and hydrogen. This study evaluates their thermal behavior and associated risks using Engineering Equation Solve software for heat transfer modeling and Areal Locations of Hazardous Atmospheres software for dispersion and explosion analysis in pipelines and storage scenarios. Results indicate that methane presents moderate and predictable risks, mainly from thermal effects in fires or Boiling Liquid Expanding Vapor Explosion events, with low toxicity. Methanol offers the safest operational profile, stable at ambient temperature and easily manageable, though it remains slightly flammable even when diluted. Ammonia shows the greatest toxic hazard, with impact distances reaching several kilometers even when emergency shutoff systems are active. Hydrogen, meanwhile, poses the most severe flammability and explosion risks, capable of autoignition and generating destructive overpressures. Thermal analysis highlights that cryogenic fuels require complex insulation systems, increasing storage costs, while methanol and gaseous hydrogen remain thermally stable but have lower energy density. The study concludes that methanol is the most practical transition fuel, when comparing thermal behavior and associated risks, while hydrogen and ammonia demand further technological and regulatory development. Proper insulation, ventilation, and automatic shutoff systems are essential to ensure safe decarbonization in maritime transport. Full article
(This article belongs to the Special Issue Advances in Green Hydrogen Energy Production)
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67 pages, 4924 KB  
Review
Current Trends and Innovations in CO2 Hydrogenation Processes
by Egydio Terziotti Neto, Lucas Alves da Silva, Heloisa Ruschel Bortolini, Rita Maria Brito Alves and Reinaldo Giudici
Processes 2026, 14(2), 293; https://doi.org/10.3390/pr14020293 - 14 Jan 2026
Cited by 2 | Viewed by 1099
Abstract
In recent years, interest in carbon dioxide (CO2) hydrogenation technologies has intensified. Driven by the continuous rise in greenhouse gas emissions and the unprecedented negative impacts of global warming, these technologies offer a viable pathway toward sustainability and support the development [...] Read more.
In recent years, interest in carbon dioxide (CO2) hydrogenation technologies has intensified. Driven by the continuous rise in greenhouse gas emissions and the unprecedented negative impacts of global warming, these technologies offer a viable pathway toward sustainability and support the development of low-carbon industrial processes. In addition to methanol and methane, other possible hydrogenation products (i.e., hydrocarbons, formic acid, acetic acid, dimethyl ether, and dimethyl carbonate) are of industrial relevance due to their wide range of applications. Therefore, this review aims to provide a comprehensive overview of the various aspects associated with thermocatalytic CO2 hydrogenation processes, from thermodynamic and kinetic studies to upscaled reactor modeling and process synthesis and optimization. The review proceeds to examine different integration strategies and optimization approaches for multi-product systems, with the objective of evaluating how distinct technologies may be combined in an integrated flowsheet. It then concludes by outlining future research opportunities in this field, particularly those related to developing comprehensive kinetic rate expressions and reactor modeling studies for routes with low technology readiness levels, the exploration of prospective reaction pathways, strategies to mitigate the dependence on green hydrogen (which, today, exhibits high costs), and the consideration of market price or product demand fluctuations in optimization studies. Overall, this review provides a solid base to support other decarbonization studies focused on hydrogenation technologies. Full article
(This article belongs to the Special Issue Feature Review Papers in Section "Chemical Processes and Systems")
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19 pages, 1163 KB  
Article
Impact of Alternative Fuels on IMO Indicators
by José Miguel Mahía-Prados, Ignacio Arias-Fernández and Manuel Romero Gómez
Gases 2026, 6(1), 4; https://doi.org/10.3390/gases6010004 - 8 Jan 2026
Cited by 1 | Viewed by 885
Abstract
This study provides a comprehensive analysis of the impact of different marine fuels such as heavy fuel oil (HFO), methane, methanol, ammonia, or hydrogen, on energy efficiency and pollutant emissions in maritime transport, using a combined application of the Energy Efficiency Design Index [...] Read more.
This study provides a comprehensive analysis of the impact of different marine fuels such as heavy fuel oil (HFO), methane, methanol, ammonia, or hydrogen, on energy efficiency and pollutant emissions in maritime transport, using a combined application of the Energy Efficiency Design Index (EEDI), Energy Efficiency Operational Indicator (EEOI), and Carbon Intensity Indicator (CII). The results show that methane offers the most balanced alternative, reducing CO2 by more than 30% and improving energy efficiency, while methanol provides an intermediate performance, eliminating sulfur and partially reducing emissions. Ammonia and hydrogen eliminate CO2 but generate NOx (nitrogen oxides) emissions that require mitigation, demonstrating that their environmental impact is not negligible. Unlike previous studies that focus on a single fuel or only on CO2, this work considers multiple pollutants, including SOx (sulfur oxides), H2O, and N2, and evaluates the economic cost of emissions under the European Union Emissions Trading System (EU ETS). Using a representative model ship, the study highlights regulatory gaps and limitations within current standards, emphasizing the need for a global system for monitoring and enforcing emissions rules to ensure a truly sustainable and decarbonized maritime sector. This integrated approach, combining energy efficiency, emissions, and economic evaluation, provides novel insights for the scientific community, regulators, and maritime operators, distinguishing itself from previous multicriteria studies by simultaneously addressing operational performance, environmental impact, and regulatory gaps such as unaccounted NOx emissions. Full article
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36 pages, 2500 KB  
Article
Driving Green: A Comprehensive Sustainability Analysis of Natural Gas-to-Methanol and Methanol-to-Gasoline Supply Chains
by Hussein Al-Yafei, Saleh Aseel, Ahmed AlNouss, Mohannad AlJarrah, Nagi Abdussamie, Ahmad Al-Kuwari, Alaa Kerret, Noman Abdul Ghafoor, Muhammad Rizki Winarno, Aisha Al-Bader, Talal Al Tamimi and Suhaila Sabbah
Sustainability 2026, 18(1), 527; https://doi.org/10.3390/su18010527 - 5 Jan 2026
Viewed by 986
Abstract
This study presents an integrated Life Cycle Sustainability Assessment (LCSA) of the Natural gas-to-methanol (NGTM) and methanol-to-gasoline (MTG) pathways using Aspen HYSYS process modeling, Environmental Life Cycle Assessment (LCA), Social Life Cycle Assessment (SLCA), and Life Cycle Costing (LCC). The results reveal significant [...] Read more.
This study presents an integrated Life Cycle Sustainability Assessment (LCSA) of the Natural gas-to-methanol (NGTM) and methanol-to-gasoline (MTG) pathways using Aspen HYSYS process modeling, Environmental Life Cycle Assessment (LCA), Social Life Cycle Assessment (SLCA), and Life Cycle Costing (LCC). The results reveal significant variability in sustainability performance across process units. The DME and MTG Reactors Section generates the highest direct greenhouse gas (GHG) emissions at 0.86 million tons CO2-eq, representing 54.9% of total global warming potential, while the Compression Section consumes 2717.5 TJ/year of energy, making it the dominant source of electricity-related indirect emissions. Distillation and Purification withdraws 31,100 Mm3/year of water—approximately 99% of total demand—yet delivers 86.6% of the overall economic surplus despite high operating costs. Social impacts concentrate in the Methanol Reactor Looping and DME and MTG Reactors Sections, with human health burdens of 305.79 and 804.22 DALYs, respectively, due to catalyst handling and high-pressure operations. Sensitivity results show that methanol purity rises from 0.9993 to 0.9994 with increasing methane content, while gasoline output decreases from 3780 to 3520 kg/h as natural gas flow increases. The findings provide process-level evidence to support sustainable development of natural gas-based fuel conversion industries, aligning with Qatar National Vision 2030 objectives for industrial diversification and lower-carbon energy systems. Full article
(This article belongs to the Section Energy Sustainability)
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30 pages, 7108 KB  
Article
Evaluating the Greenhouse Gas Fuel Intensity of Marine Fuels Under the Maritime Net-Zero Framework
by Murat Bayraktar, Kubilay Bayramoğlu and Onur Yuksel
Sustainability 2026, 18(1), 184; https://doi.org/10.3390/su18010184 - 24 Dec 2025
Viewed by 1287
Abstract
Greenhouse gas (GHG) emissions from maritime transport account for nearly 3% of global totals, making the decarbonisation of this sector a critical priority. In response, the International Maritime Organization (IMO) adopted the GHG Strategy, targeting the full decarbonisation of international shipping by 2050, [...] Read more.
Greenhouse gas (GHG) emissions from maritime transport account for nearly 3% of global totals, making the decarbonisation of this sector a critical priority. In response, the International Maritime Organization (IMO) adopted the GHG Strategy, targeting the full decarbonisation of international shipping by 2050, with interim milestones in 2030 and 2040. This study evaluates the greenhouse gas fuel intensity of three representative vessel types, an oil tanker, a container ship, and a bulk carrier, using one-year operational fuel consumption data in line with the Regulations of the IMO Net-Zero Framework. Both conventional fuels, including conventional marine fuels, and alternative options, encompassing liquefied natural gas (LNG), e-hydrogen, e-ammonia, e-methanol, and biodiesel, are assessed for compliance during 2028–2035. The findings reveal that conventional fuels are unable to meet future targets, resulting in significant compliance deficits and balancing costs of remedial units. LNG provides short-term benefits but is limited by methane slip. In contrast, e-hydrogen and e-ammonia enable long-term compliance and generate surplus units. E-methanol shows a partial potential, while biodiesel delivers only modest improvements. The results underscore the need for a transition toward near-zero-well-to-wake-emission fuels. This study contributes by combining life cycle assessments with regulatory compliance analysis, offering insights for policymakers and industry stakeholders. Full article
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35 pages, 5245 KB  
Article
Activated Carbon Derived from Plane Tree (Platanus) Fruits by Ba(OH)2 Activation and Its Possible Application as Catalyst Support in Reforming Processes: Kinetic and Thermodynamic Study of Thermal Reactivation with Mechanistic Investigation
by Bojan Janković, Milena Marinović-Cincović, Jovana Bukumira, Milena Pijović-Radovanović and Vladimir Dodevski
Processes 2025, 13(12), 3835; https://doi.org/10.3390/pr13123835 - 27 Nov 2025
Viewed by 665
Abstract
In this study, a novel activated carbon (AC) (AC-Ba(OH)2) was synthesized through a three-step process (including hydrothermal carbonization (at 250 °C), alkali activation by Ba(OH)2, and pyrolysis (at 850 °C)), from Plane tree fruits (PTFs). By using various experimental [...] Read more.
In this study, a novel activated carbon (AC) (AC-Ba(OH)2) was synthesized through a three-step process (including hydrothermal carbonization (at 250 °C), alkali activation by Ba(OH)2, and pyrolysis (at 850 °C)), from Plane tree fruits (PTFs). By using various experimental methods for material characterization, it was established that the resulting material possesses a variety of oxygen functional groups, rich in alkaline earth oxides (BaO/CaO), SiO2, consisting of graphitized carbon with graphene structures. A detailed kinetic and thermodynamic analysis of AC-Ba(OH)2 thermal restoring was also carried out. Thermodynamic analysis revealed the existence of a true thermodynamic compensation effect (TCE) during restoration. Restoration was controlled by entropy, where experimental temperatures are above the iso-entropic temperature, i.e., the temperature where contributions of enthalpy and entropy to activation free energy are balanced. Kinetic modeling has shown that restoration allows carbon material to be significantly modified by removing oxygen-containing groups via diffusion, changing active sites on the surface, and preparing material for catalyst support. CaO and SiO2 act as catalysts, while BaO alters graphene surface properties. Isothermal prediction tests have shown an extremely high long-term stability of modified AC-Ba(OH)2, supporting an elevated activity, selectivity, and lifetime, as well. The restoring process resulted in an energy consumption of 0.762 kWh, which is equivalent to the reactivation of AC with a lower specific surface area. Manufactured AC and its thermally modified counterpart can be used as both a catalyst support and catalyst for reforming processes, such as methanol synthesis, biogas purification, and dry reforming of methane. Full article
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19 pages, 1963 KB  
Article
Design, Optimization, and Process Integration of a Methanol-to-Olefin Plant
by Nasser Saad Alosaimi, Abdulaziz Althabet, Irfan Wazeer, Mourad Boumaza and Mohamed K. Hadj-Kali
Processes 2025, 13(12), 3806; https://doi.org/10.3390/pr13123806 - 25 Nov 2025
Viewed by 1756
Abstract
The methanol-to-olefins (MTO) process offers a viable alternative to traditional naphtha cracking for producing light olefins, providing flexibility in feedstock sources and the potential for reduced energy consumption. This study presents a detailed plant-wide design of an MTO process, developed and optimized to [...] Read more.
The methanol-to-olefins (MTO) process offers a viable alternative to traditional naphtha cracking for producing light olefins, providing flexibility in feedstock sources and the potential for reduced energy consumption. This study presents a detailed plant-wide design of an MTO process, developed and optimized to increase ethylene and propylene yields while reducing energy consumption. The methodology includes comprehensive reactor modeling of a fast fluidized-bed reactor–regenerator system, accounting for coke formation kinetics, along with rigorous process simulation for the subsequent separation and purification of products. A six-column distillation train has been designed and optimized for the recovery of polymer-grade ethylene and propylene, while dual-stage CO2 absorption units ensure complete removal of carbon dioxide. Pinch analysis is used to identify opportunities for heat integration, resulting in an optimized heat-exchanger network that significantly reduces the need for external heating and cooling utilities. The results show that the optimized MTO design achieves a methanol conversion rate of over 99.9% and produces a propylene-rich product stream with a propylene-to-ethylene ratio of approximately 1.8, while maintaining a high purity level exceeding 99.5%. By implementing heat integration and recycling by-products, including using off-gas methane as furnace fuel and repurposing waste heat for steam generation, the plant reduces utility requirements by more than 85%, significantly improving energy efficiency. An economic evaluation shows a favorable payback period of approximately 5.4 years and an internal rate of return of 15–16%, confirming the viability and industrial potential of the integrated MTO process for sustainable olefin production. Full article
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22 pages, 1295 KB  
Review
Closing the Loop: How Regenerative Robust Gasification Enhances Recycling and Supply Chain Resilience
by Bruce Welt, Calvin Lakhan, Jacob Gazaleh, Charles Swearingen and Ziynet Boz
Recycling 2025, 10(6), 209; https://doi.org/10.3390/recycling10060209 - 14 Nov 2025
Viewed by 1653
Abstract
Municipal solid waste (MSW) recycling is constrained by contamination, heterogeneity, and infrastructure built around material-specific pathways. We introduce effectiveness-normalized greenhouse gas (GHG) emissions as a system-level metric that adjusts reported process burdens by feedstock eligibility (Effectiveness Fraction, EF) and carbon recovery efficiency (CRE) [...] Read more.
Municipal solid waste (MSW) recycling is constrained by contamination, heterogeneity, and infrastructure built around material-specific pathways. We introduce effectiveness-normalized greenhouse gas (GHG) emissions as a system-level metric that adjusts reported process burdens by feedstock eligibility (Effectiveness Fraction, EF) and carbon recovery efficiency (CRE) to reflect real-world MSW conditions. Using published LCA data and engineering estimates, we benchmark six pathways, mechanical recycling, PET depolymerization, enzymatic depolymerization, pyrolysis, supercritical water gasification (SCWG), and Regenerative Robust Gasification (RRG), at the scale of mixed MSW. Normalizing for EF and CRE reveals large differences between process-level and system-level performance. Mechanical recycling and PET depolymerization show low process intensities yet high normalized impacts because they can treat only a small share of plastics in MSW. SCWG performs well at broader eligibility. RRG, a plasma-assisted molten-bath approach integrated with methanol synthesis, maintains the lowest normalized impact (~1.6 t CO2e per ton of recycled polymer) while accepting virtually all organics in MSW and vitrifying inorganics. Modeled methanol yields are ~200–300 gal·t−1 without external hydrogen and up to ~800 gal·t−1 with renewable methane reforming. The metric clarifies trade-offs for policy and investment by rewarding technologies that maximize diversion and carbon retention. We discuss how effectiveness-normalized results can be incorporated into LCA practice and Extended Producer Responsibility (EPR) frameworks and outline research needs in techno-economics, regional scalability, hydrogen sourcing, and uncertainty analysis. Findings support aligning infrastructure and procurement with robust, scalable routes that deliver circular manufacturing from heterogeneous MSW. Full article
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