Waste Gas Utilization

Gas processing, conditioning and gas enrichment

The industrial sector accounts for about 38% of the total global energy consumption in 2018. Within the industrial sector, the major energy consuming sectors are chemicals & petrochemicals, iron & steel and refining. Depending on operating practices & geography, these sectors account for about 15-20%, 10-18% and 6-8% of the total industrial energy consumption respectively.

Depending on the operating conditions and degree of combustion, the process gases can have widely varying characteristics and a significant amount of energy-rich components like CO, CH4 and H2, apart from CO2 and N2. However, current industrial practices are not designed to fully exploit the value/energy content of these gases and use them either as low value fuels in captive power plants, reheating furnaces or stoves or flare them, leading to lower energy efficiency and higher GHG emissions. In fact, in 2018, the industrial sector accounted for nearly 6 GT of CO2 emissions.

Appropriately designed waste gas conditioning, enrichment and utilization systems, suitably integrated with the existing main process units, provides a pathway for improving the overall energy efficiency and significantly reducing CO2 emissions from industrial facilities. Value creation is possible by converting waste gases into high-value products in an energy-efficient and environmentally sustainable manner instead of using them merely as low-value in-plant fuels.

Dastur Energy’s is applying its IP-based business-driven solutions for enrichment and carbon capture of waste gases at one of the largest steel plants in North America. The waste gas composition is conditioned to create a CO2 rich gas stream to enable cost-effective carbon capture (30-40 US$/tonne of CO2), as well as a hydrogen-rich and energy-rich syngas stream, which can be used for producing clean power or clean products. Our solutions offer the option to calibrate the extent of the gas conditioning, gas enrichment and the syngas quality (CO/H2 ratio), thus offering the flexibility of different operating paradigms and end-products.

The key components of our solution include:

  • Appropriate and calibrated conditioning of the industrial process gases to enhance the energy content.

  • Designing suitable CO2 capture schemes with the appropriate source, scale and technology.

  • Utilizing the energy-rich syngas for the production of value-added products like power, DRI and chemicals such as methanol and derivates.

  • Appropriate recycling schemes to improve the overall energy utilization.

  • A bespoke combination of gas conditioning elements and reaction types (high temp. or low temp.) to get the desired gas composition, optimal reactor sizing and steam & catalyst consumption.

Dastur Energy has also conceptualized and designed multiple projects for the development of scalable, flexible and cost-competitive waste gas utilization schemes for various industries in the Middle-East and India, thus providing a solution for significant reduction of energy consumption and CO2 emissions from industrial waste gases. 

Technology Pillars