Conversion of CO2 to Alkyl Carbonates using Ethylene Oxide as Feedstock

The challenges associated with CO2 capture, transport and storage have been well documented. Therefore, all possible options must be pursued for abatement of global CO2 emissions including CO2-based products. A new generation of CO2-capture technologies being developed with federally funded projects could show market-driven adoption if CO2 were used to manufacture competitively value-added products. The major objective of the Phase IIB Sequential project is to integrate the E3Tec’s DMC conversion process with GTI’s membrane-based CO2 capture technology. Integration of the two proven technologies will significantly enhance acceptance of the integrated process of CO2 capture and conversion to dimethyl carbonate (DMC) by the CO2 generating plants as well as the manufacturers of specialty chemicals. Phase II R&D has advanced the technology from TRL-3 to TRL-4 of Lab Testing/Validation of Alpha Prototype Components/Process. Phase IIB is expected to advance the integrated process from TRL-3 to TR-4, to bring in-par with the individual membrane-based CO2 capture and conversion to DMC technologies. The work plan consists of: a) performance testing of the membrane reactor for direct conversion of flue gas CO2 to intermediate species of DMC; b) ASPEN Plus® process analysis of the integrates process; c) techno-economic analysis (TEA) and life cycle analysis (LCA) to evaluate the merits of the integrated process vs. separate CO2 capture and conversion to DMC; and d) Front-End Engineering Design (FEED) of a pilot plant for implementation in Phase III. Commercial Applications and Other Benefits: The numerous and expanding uses of DMC and derived high-value products make it an ideal candidate for utilization of captured CO2. The major applications with rapidly expanding global market of DMC are: a) production of polycarbonate resins; b) solvent with low VOC replacing ketones; c) potential use in lithium-ion batteries; d) intermediate for polyurethane and e) candidate as oxygenated fuel additive in diesel. The economic, environmental and social benefits of CO2-based DMC production in the US are fairly justified.