Muhammad Farooq Fareed

Global warming, high energy consumption, resource depletion, and excessive waste generation are critical challenges facing our planet. Carbon Capture, Utilization, and Storage (CCUS) facilities are designed to mitigate these impacts. These facilities not only capture carbon and convert it into valuable products but also aim to minimize energy consumption and reduce carbon footprints worldwide. Key performance indicators of their effectiveness include reductions in energy consumption, efficient resource utilization, minimal waste generation, and the CO2 footprint per kilogram or ton of product. If multiple CCUS facilities are developed based on the same principles but exhibit high carbon and energy footprints, their overall effectiveness will not contribute positively to global sustainability end with either same or higher. We initiated with the same innovative approach. The existing CCUS plant processes raw CO2 by-products from glycol, converting them into food-grade CO2. The plant is designed to compress and purify approximately 1,500 tons per day of raw CO2 and is capable of producing both gaseous and liquid food-grade CO2. This significant innovation has presented numerous challenges, ranging from conceptual design to sustainable operation to minimize waste and energy. Issues such as design simulation, engineering challenges, design concepts, frequent shutdowns, leakages, equipment failures, unit damages, and prolonged plant outages have posed threats to process safety and EHSS. These challenges have resulted in substantial production losses, high repair costs, significant replacement and engineering expenses, and extended production interruptions. However, innovative solutions have resolved numerous engineering challenges, enabling the unit to operate with high efficiency, maximum resource utilization, and minimal waste generation. The facility was initially designed with a high carbon and energy footprint; however, after implementing these improvements, the footprint has been drastically reduced to a minimum. Our approach not only resolves all plant issues, but also enables further optimization and utilization, addresses potential problems, and reduces energy footprints. A smart solution is required to enhance CO2 liquid production, recycle and reuse waste with minimal energy use, and minimize sustainability impacts while simultaneously increasing production. Furthermore, this solution should not adversely affect the process or unit operations and should require minimal modifications. Positive impacts of CO2 production in sustainability efforts by United and Sabic. Reduction in GHG emissions by over 20%, an energy reduction exceeding 11%, a water usage reduction surpassing 11%, and an improvement in material efficiency of more than 59.1%. Through further innovative initiatives, waste recycling and water consumption have been reduced by over 97%, converting waste into useful water. Energy optimization has led to input reductions of more than 75%, and 99.9% of exhausted CO2 streams are recycled and reused. Reducing CO2 emissions is a key objective of SABIC's sustainability strategy. It is estimated that more than 500,000 tons of CO2 emissions will be saved annually, generating over 10 million dollars in revenue each year from the sale of CO2 as a valuable product.

Co-author/s:

Abdullah Al-tamimi, Process Manager, Sabic.