An Integrated Process Engineering Approach for the Optimal Implementation of Carbon Capture and Utilization Superstructure in Refineries

• Grant number: 25/28479-5
• Support Opportunities: Scholarships in Brazil - Doctorate
• Start date: May 01, 2026
• End date: May 31, 2029
• Field of knowledge: Engineering - Chemical Engineering - Chemical Process Industries
• Principal Investigator: Rita Maria de Brito Alves
• Grantee: Egydio Terziotti Neto
• Host Institution: Escola Politécnica (EP). Universidade de São Paulo (USP). São Paulo , SP, Brazil

Abstract

This project proposes the development of an integrated process engineering approach aimed at the synthesis, modeling, and optimization of a superstructure for carbon capture and utilization (CCU) in Brazilian refineries, considering the high environmental impact of the oil and gas sector, which is currently responsible for approximately 80% of national carbon dioxide (CO2) emissions. In this context, although the adoption of carbon capture and storage (CCS) technologies by the oil and gas sector represents a relevant advancement in reducing environmental impacts, such initiatives cover only a fraction of the total emissions from the oil processing chain, highlighting the need for more comprehensive and economically viable solutions. Accordingly, the project seeks to identify critical emission points along the petroleum value chain (with focus in refineries) and to propose alternatives based on the conversion of CO2 into higher value-added products, through the use of mathematical modeling, process simulation, and process optimization tools. A growing scientific interest in this field is evident, as reflected by the general increase in publications and patents related to CO2 capture and conversion in recent years. However, significant gaps remain, such as the lack of process modeling and simulation studies that incorporate not only assertive decision-making regarding multiple possible end products, but also energy integration, hybrid capture techniques, or the assessment of uncertainties associated with exogenous factors, including market fluctuations, demand variability, and constraints in energy supply, among others. In this context, the present project aims to formulate an integrated process for CO2 capture and conversion through the use of superstructures appropriately representing the system under study. This will make it possible to determine, under future uncertainty regarding products obtained through CO2 conversion, the most suitable production route and the most profitable products to be derived from CO2 emitted by oil refineries. To that end, the project proposes the use of process simulation and mathematical system modeling techniques, potentially combined with surrogate model development to ensure adequate representation of complex unit operations. This will enable the appropriate solution of the proposed stochastic optimization problem. The project is expected to assess the feasibility of integrating CO¿ emissions from the oil industry into an industrial structure for carbon capture and conversion under an uncertain future scenario. In doing so, it will provide a detailed and rigorous understanding of how the environmental impacts caused by such a significant economic sector could be mitigated. Ultimately, the project aims to deliver relevant contributions to the scientific and industrial communities, fostering a more sustainable future that is less dependent on fossil fuels. (AU)