Progress Report 1: Chemical CO2 Fixation

A Step Closer to the Ultimate Form of Recycling

We are turning CO2 into methanol, which is a raw material for chemicals. We have been running a pilot plant for a year, with the goal of commercializing this new technology that turns the common wisdom on its head. We have made a big step toward achieving the ultimate in recycling, and have found new challenges that need to be tackled.

Clearing One Hurdle on the Road to Commercialization

Mitsui Chemicals participates in the Project for Chemical CO2 Fixation & Utilization by the Research Institute of Innovative Technology for the Earth (RITE), and has continued to develop catalysts to synthesize methanol from CO2 and hydrogen. In 2009, we built a pilot plant in our Osaka Works, and we have begun operation with the aim of commercializing a technology for synthesizing methanol using CO2 contained in exhaust gas as a raw material.

One of the goals of the pilot project was to use actual factory exhaust, rather than pure CO2. We are using CO2 that is separated and purified from exhaust containing a wide range of constituents such as NOx. Another goal was to create a catalyst that could stand up to industrial levels of use.

“We were very nervous about whether we would really get methanol out, but we got the expected quality. I think that we have just cleared one of the hurdles,” says Tatsumi Matsushita, senior researcher at the Process Technology Center, which oversees the construction and operation of the pilot plant.

But this doesn't mean that the experiment went smoothly by any stretch. At first, they had one problem after another, and for a while they were getting anxious because they could not get the pilot to run stably for continuous periods. At the same time, they also found new challenges.

“It uses more electricity and steam than we expected,” says Matsushita. “The process itself will not be viable unless we can reduce total CO2, in terms of the energy budget as well. But the conditions for achieving this have also become clear.”

In 2010 We Will Design Industrial Processes and Consider Business Models

“In order to overcome these challenges,” says Matsushita, “in fiscal 2011 we plan to add even more innovative technologies to our existing technologies, and advance energy conservation. The other thing is getting hydrogen. We're currently refining hydrogen generated as a by-product in our Works' emissions, but we're going to work to expand our sources of hydrogen, starting with using hydrogen produced as a by-product of coke furnaces and other sources directly.”

Our future target is to use sunlight and other natural energy to get hydrogen by splitting water. To this end, we are developing photocatalysts and other technologies. This will enable us to make methanol from CO2 and water.
Matsushita continues: “This process produces methanol and water. If we can make hydrogen from that water, we will have achieved the ultimate form of recycling: carbon plus water. This would be truly revolutionary, because it means that even when we run out of fossil fuels, we'll still be able to make chemical raw materials and fuel.”

There has been a massive reaction since the announcement in 2009, and requests to come and observe are pouring in, including from overseas.
“Fiscal 2011 will be our ‘crucial year' for commercialization,” says Matsushita. “I think you can say that the technologies we've developed so far are ready, but we are going to add another round of improvements. At the same time, we will start designing an industrial process capable of handling hundreds of thousands of tons.”

Will a place with a CO2 source be best? Or a place with a hydrogen source? Or will it be a place with a wealth of natural energy? A wide range of divisions at Mitsui Chemicals are working together, and starting to consider business models for the ultimate form of recycling.


Tatsumi Matsushita
Senior Researcher
Chemical Process Unit
Process Technology Center
Production & Technology Center

The Concept of Chemical Fixation of CO2

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Results from “Project for Chemical CO2 Fixation & Utilization (1990-1999; supported by NEDO),” with RITE.