The Bayer MaterialScience Carbon Monoxide Pipeline
We apologize in advance for the disorganized nature of this dispatch. There's a lot of ground to cover just to get to the primary, some perhaps ironic, points.
First, we remind you that we have now documented a number of technologies whereby Carbon Dioxide can be productively recycled, via chemical conversion into the industrially-valuable Carbon Monoxide.
A few examples can be seen via:
West Virginia Coal Association | Standard Oil Electrolyzes CO2 to Carbon Monoxide | Research & Development; concerning: "US Patent 4,668,349 - Electrocatalytic Reduction of CO2 by Square Planar Transition Metal Complexes; 1987; Assignee: The Standard Oil Company; Abstract: A process for the electrocatalytic reduction of carbon dioxide ... to carbon monoxide"; and, most recently:
West Virginia Coal Association | France Uses Hydrogen to Convert CO2 to Carbon Monoxide | Research & Development; concerning: "United States Patent Application 20030113244 - Producing Carbon Monoxide by Reverse Conversion; 2003; Inventors: Rene Dupont, et. al., France; Correspondence (and presumed eventual Assignee of Rights): Air Liquide; Houston, TX; Abstract: The invention concerns a method for producing carbon monoxide (from) a gas mixture rich in CO2".
And, those would be in addition to related and similar technologies, as seen for just one example in:
West Virginia Coal Association | Utah Recycles CO2 | Research & Development; which concerns a technology developed in part by our USDOE: "Co-Electrolysis of Steam and Carbon Dioxide as Feed to a Methanation Reaction; Lyman Frost, Joseph Hartvigsen and S. Elangovan; Ceramatec, Inc, UT;
Abstract: Solid oxide fuel cells can be operated in reverse by applying an electric potential across the fuel cells and forcing the oxygen ion to flow in the opposite direction from the fuel cell mode. If a mixture of high temperature steam and carbon dioxide are fed to a fuel cell stack operating in this electrolysis mode, the result will be a mixture of carbon monoxide and hydrogen. By adjusting the input ratios of steam and carbon dioxide, the output of the electrolysis system can be modified to be in the proper ratio for the formation of a number of different hydrocarbons by catalytic process through either Fischer Tropsch or methanation reactions";
wherein Carbon Dioxide and H2O are processed together to form a blend of Hydrogen and Carbon Monoxide directly suitable for the catalytic chemical synthesis of liquid and gaseous hydrocarbon fuels.
One value of Carbon Monoxide alone, especially as extracted from Carbon Dioxide, lies in the fact that it can and does serve as one basic raw material in the synthesis of certain high-volume plastics, wherein any CO2 from which the Carbon Monoxide might have been derived would be chemically and permanently, and productively, profitably, "sequestered".
One example of such plastics-synthesis Carbon Monoxide utilization technology can be seen in:
"United States Patent: 5349102 - Preparation of Phenyl Carbonates or Polycarbonates; 1994; The Dow Chemical Company, MI; Abstract: A process for the preparation of an aromatic carbonate or polycarbonate from a phenol or bisphenol, methanol, carbon monoxide and oxygen".
And, note, in the above, the multiple routes for Carbon Dioxide utilization, since, not only can the "carbon monoxide" be made from CO2, but, as seen for only one example in:
West Virginia Coal Association | California March 2012 Efficient CO2 to Methanol | Research & Development; concerning: "United States Patent 8,138,380 - Electrolysis of Carbon Dioxide ... for Production of Methanol; 2012; Inventors: George Olah and G.K. Surya Prakash; Assignee: University of Southern California; Abstract: An environmentally beneficial method of producing methanol from varied sources of carbon dioxide including flue gases of fossil fuel burning power plants";
so can the needed "methanol".
Additional, similar plastics synthesis technology is disclosed in:
"United States Patent: 4806674 - Preparation of Urethanes by Oxidative Carbonylation of Amines; 1989; E.I. Dupont De Nemours and Company; Abstract: A process for preparing urethanes by reacting a primary or secondary amine with carbon monoxide, an alcohol, a catalytic quantity of a compound or complex of palladium, platinum or rhodium and a stoichiometric quantity of a copper(II) salt of a monocarboxylic acid";
and, of special interest to us herein:
"United States Patent: 4582923 - Process for the Production of Urethanes; 1986; Bayer AG, Germany; Abstract: Urethanes are made by reacting a primary amine with carbon monoxide".
And, such use of Carbon Monoxide would be in addition to Bayer's direct use, as indicated in:
West Virginia Coal Association | Bayer Is Converting Coal Power Plant CO2 Into Plastics | Research & Development; concerning: "'Bayer Material Science CO2-to-Plastics Pilot Plant, Germany';
In February 2011, Bayer MaterialScience started a new pilot plant (in the) North Rhine-Westphalia state of Germany for producing plastics from carbon dioxide (CO2). It will be used to develop polyurethanes from the waste gas released during power generation. ...Bayer aims to use CO2 as an alternative to production of polymer materials from fossil fuels",
of Carbon Dioxide itself in the synthesis of other "polymer materials".
We must note, as an aside, in order to do what we can to help prevent confusion although this will be an oversimplification, that, in the production of some types of "polyurethanes", two separate chemicals are reacted together. One is, generically, known as "polyol", which is short for "poly alcohol". And, some polyols can be synthesized using Carbon Dioxide as a raw material; as we think, based on rather unspecific reports, is being done with the CO2 reclaimed from the North Rhine-Westphalia power plant.
The other reactant is, again generally, or generically, known as an "isocyanate" or "poly-isocyanate". And, some isocyanates can be synthesized using Carbon Monoxide as one primary raw material.
But, concerning where Bayer might get the Carbon Monoxide for use and consumption in a process like that disclosed in the above-cited "United States Patent 4,582,923 - Process for the Production of Urethanes", we remind you of:
West Virginia Coal Association | Bayer Improves Coal + CO2 = Carbon Monoxide | Research & Development; concerning: United States Patent 7,473,286 - Carbon Monoxide Generator; 2009; Assignee: Bayer Material Science, AG, Germany";
wherein they disclose that Carbon Monoxide can be manufactured by reacting Carbon Dioxide, as recovered from whatever handy source, with hot Coal.
In any case, whichever technology they are employing, Bayer, in Germany, is recovering Carbon Dioxide from an industrial process source; and, is converting that CO2 into Carbon Monoxide, which they would like to use, or perhaps now are using, at one of their factories for the production of plastics.
German environmentalists do not want them to thus recycle and productively consume Carbon Dioxide.
As we explain via excerpts from the initial link in this dispatch, with additional links and excerpts following:
"'Raw Materials Network On The Rhine'
Carbon monoxide (CO) - - an important raw material for the chemical industry. Production at the Bayer site in Krefeld-Uerdingen will not be sufficient to meet long-term demand. The company is therefore planning to supply the facilities here with CO by means of a pipeline running from CHEMPARK Dormagen. This pipeline, which is 67 kilometers long, is almost complete, but has not yet commenced operation due to legal disputes and regulatory requirements.
Most of the CO pipeline runs below the ground on the right side of the Rhine. It mostly passes through farmland and woodland, but also makes use of existing infrastructure routes (railways, highways, etc.).
A large section of the pipeline was also laid parallel to a natural gas pipeline.
The State Parliament of North Rhine-Westphalia (NRW) has determined on several occasions that the CO pipeline is of benefit to the state. The statute relating to its construction was supported and unanimously adopted by all parties. After all, the project will strengthen the economy of North Rhine-Westphalia. It will enable the Krefeld-Uerdingen site to be part of a reliable, safe and environmentally compatible CO network.
The pipeline will also help to protect the environment because the climate gas Carbon Dioxide is generated as a by-product at the Dormagen site. Rather than releasing it into the atmosphere, the CO2 is to be converted into carbon monoxide and sent through the pipeline to Krefeld-Uerdingen.
Bayer MaterialScience needs CO there to produce the high-quality plastic polycarbonate, among other things.
(Note, for emphasis: Bayer is reclaiming the Carbon Dioxide byproduct of one industrial process, converting that Carbon Dioxide into Carbon Monoxide, and, then, consuming that CO2-derived Carbon Monoxide, chemically transforming it, in the synthesis of durable, high-value plastics. Not only is Carbon Dioxide being, in fact, destroyed through the complete process; but, such use and consumption of Carbon Dioxide, through Carbon Monoxide, forestalls and makes unnecessary the extraction of other, natural, resources.)
Pipelines are both the safest and the most environmentally friendly means of transport for many liquid and gaseous substances. Bayer has been operating a variety of supply pipelines, including other CO pipelines, for many years.
The comprehensive safety concept for the new carbon monoxide pipeline exceeds statutory requirements. For example, it will be operated at a pressure of no more than 13.5 bar, even though it has a design pressure of 100 bar and has been tested at pressures in excess of 200 bar.
The plastic-coated steel pipes measure 25 cm in diameter. Their steel is very strong, yet deformable, which protects the pipes against vibrations and earthquakes, for example. They are located at least 1.40 meters below the surface, even though a depth of just one meter is specified by law. The pipeline is monitored by an operations control center staffed around the clock, and it is subject to regular checks by TÜV (technical inspection authorities).
Commissioning of the pipeline is on hold, in part due to legal disputes between local residents and the Düsseldorf district authority (Bezirksregierung Düsseldorf), which is the responsible governmental authority. These disputes have been ongoing for years. In the principal proceedings, the Administrative Court in Düsseldorf (Verwaltungsgericht Düsseldorf) last delivered a judgment in May 2011. This largely confirmed the legal basis for the project, i.e. the planning approval and the Pipeline Act (Rohrleitungsgesetz).
The judges raised no objection to either the pipe material or the route of the pipeline. They also confirmed the project is of benefit to the population of North Rhine-Westphalia. There are just three subtopics related to seismic safety that still need to be looked at by the Düsseldorf District Authority.
The authority therefore issued a supplementary planning ruling in August 2012 clarifying the improvements demanded by the Administrative Court. Bayer MaterialScience considers this to be an important milestone.
Another prerequisite for commencing operation of the pipeline was for the district authority to approve a number of plan deviations, for which Bayer MaterialScience submitted an application in April 2011. The authority has since confirmed to the company that the application is complete and ready for public inspection. This means Bayer MaterialScience can initiate the process of displaying the documents, thus involving the public.
The pipeline will only become operational once all the conditions have been satisfied. This also includes a favorable court decision."
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Again, independent news reports we've been able find are sparse and incomplete; but, we think that the pipeline is now operational, despite the perverse efforts of supposedly altruistic environmentalists who, according to other news reports we're not directly referencing or including links to, opposed the Carbon Monoxide pipeline, even though, as noted above, Bayer's CO pipeline was, for much of its length, "laid parallel to" an already-existing "natural gas pipeline"; and, which natural gas pipeline nobody, strangely, seems to have any public objections to. Although, as suggested by:Sierra Club took $26 million from natural gas lobby to battle coal industry | The Daily Caller; "(The) Sierra Club, America’s oldest and most august environmental organization, accepted millions of dollars in donations from one of the nation’s biggest natural gas-drilling companies for a program lambasting coal-fired power plants as environmental evildoers.The total take for John Muir’s conservation group? A whopping $26 million over four years from Chesapeake Energy and its subsidiaries, mostly through Chesapeake CEO Aubrey McClendon. The news rocked the environmental movement, sent the Sierra Club headlong into explanation mode, angered coal companies that the organization targeted with natural gas money";
there could well be a logical, if indefensible, explanation for that.
And, maybe it's Bayer that should be worried - - about an important piece of their Carbon Dioxide-recycling and raw material supply infrastructure, since, as seen, for just a few out of many, many examples, in:
West Virginia gas pipeline explosion – just a drop in the disaster bucket - CSMonitor.com; "Christian Science Monitor; December 12, 2012; West Virginia gas line explosion - just a drop in the disaster bucket. The fireball explosion Tuesday of an interstate natural gas transmission line in West Virginia, which left behind a huge jet of flame that burned for more an hour and melted four lanes of I-77, is just one of scores of accidents and explosions involving natural gas lines this year"; and:
Pipeline Explosion Kills 10 Campers in N.M. - ABC News; "Federal, state and local authorities are investigating the cause of Saturday’s natural gas pipeline explosion that killed five adults and five children and left two other people in critical condition in southeast New Mexico"; and:
Allentown pipeline explosion revives natural gas worries - USATODAY.com; "Transporting natural gas by pipeline is the safest way to move that energy," says Carl Weimer, executive director of the Pipeline Safety Trust, ... . "Still, every nine or 10 days on average someone ends up dead or in the hospital";
natural gas pipelines ain't the safest, most secure things in the world to be lying down next to, or, hanging your economic hat on, even though most "environmentalists", and the folks who listen to them, tout natural gas as the greatest thing since sliced bread.
But, the point of it all is this:
Carbon Dioxide, as is co-produced in only a very small way, relative to natural sources of emission, such as the Earth's inexorable, unstoppable, un-taxable processes of planetary volcanism, from our economically essential use of Coal in the generation of truly abundant and genuinely affordable electric power, is a valuable raw material resource.
Carbon Dioxide can be, and is being, on a commercial and industrial basis, converted into Carbon Monoxide.
And, Carbon Monoxide can be, and is being, used as a basic raw material for the synthesis of high-volume, high-performance, highly-profitable plastics; plastics wherein the CO2 consumed in the manufacture of the Carbon Monoxide is being forever, and productively, "sequestered".