A new study led by Professor Jhuma Sadhukhan at Surrey University has demonstrated the environmental benefits of turning CO₂ emissions into key chemical ingredients.
As part of the Flue2Chem initiative, researchers for the first time assessed the entire life cycle of converting waste gases from steel and paper mills into alcohol ethoxylate, a surfactant for consumer goods, and low-medium distillate range liquid fuel.
The study, published in the Journal of CO2 Utilization, found the approach reduces global warming potential (GWP) by around 82 per cent for paper mill emissions and nearly half for the steel mill industry compared to fossil-based surfactant production.
In a statement, co-author Professor Jin Xuan, Associate Dean of Research and Innovation at Surrey, said: “For decades, fossil fuels have been the backbone of manufacturing, not just as an energy source but as a key component in the products people use daily. However, this reliance has come at a high environmental cost.
“Our findings show that waste CO₂ can be part of the solution rather than the problem. This isn’t just about cutting emissions – it’s about creating a circular carbon economy where waste becomes the building blocks of essential products and fuel.”
Life cycle assessments show that CO₂-based products offer significant environmental benefits. However, a techno-economic analysis highlights key challenges, such as high costs and limited hydrogen supply, which are critical for converting CO₂ into surfactants. Given the energy-intensive nature of the process, the study emphasises the need for further investment in renewable energy infrastructure.
A separate Surrey-led study, published in Digital Chemical Engineering, looked at the economic feasibility of different production methods and found that the CO₂ capture route remains more expensive, at $8/kg compared to $3.75/kg for fossil-based sources. However, technological advances and increasing demand for sustainable products will likely help bridge the gap, making CO₂-derived surfactants a cost-effective alternative in future.
Consumer industries are currently valued at over £73bn in the UK alone. The global surfactants market size was valued at $43.2bn in 2023 and is projected to grow at a CAGR of 5.3 per cent from 2024 to 2030.
The Flue2Chem initiative includes BASF, Johnson Matthey, P&G, and Tata Steel as industrial partners.
Motorists need incentives to buy EVs - report
Frankly a £1000 cut on VAT will make little difference if buyers cannot be tempted by the completely unsustainable level of discounting being offered...