An engineering-environmental-economic-energy assessment for integrated air pollutants reduction, CO2 capture and utilization exemplified by the high-gravity process

In this study, a high-gravity (HiGee) process incorporating CO2 and NOx reduction from flue gas in a petrochemical plant coupled with petroleum coke fly ash (PCFA) treatment was established. The performance of HiGee was systematically evaluated from the engineering, environmental, economic, and energy aspects (a total of 15 key performance indicators) to establish the air pollution, energy efficiency, waste utilization nexus. The engineering performance was evaluated that lower energy consumption of 78 kWh/t-CO2 can be achieved at a capture capacity of 600 kg CO2/t-PCFA. A net emission reduction of 327.3 kg-CO2/t-PCFA could be determined based on six environmental impact indicators. A cost-benefit analysis was conducted using operating cost, product sale, carbon credit, and savings in air pollution fees to present a better technological selection compared to existing carbon capture and storage plants. The waste heat recovery from the flue gas via the HiGee process could be measured via moisture condensation and attendant elimination of white smog emissions. Retrofitted heat recovery and energy intensity up to 131.8 kJ/t-PCFA and 0.21 kWh/t-PCFA were assessed. Finally, a comprehensive analysis of the HiGee process based on three daily load scenarios of CO2 capture scale were conducted, suggesting an optimal operating condition of the HiGee for generating profitability. [Display omitted] •CO2 daily capture of 600 kg and energy consumption of 80 kWh/t-CO2 were evaluated.•Marginal cost of 31.4 USD/t-CO2 and capture scale of 0.79 t-CO2/day were assessed.•Impacts of global warming potential, human health and ecosystem were quantified.•Comprehensive evaluation of HiG was identified using 15 KPI by 4E analysis.