Periodic Reporting for period 2 - HIGFLY (HIGee to Furanic-based jet Fuel technologY)
Reporting period: 2022-07-01 to 2023-12-31
In a net-zero Europe 2050, flying will remain an important form of mobility. To be able to meet the strict and ambitious targets on CO2 emissions set by the aviation sector, the development and prompt deployment of novel technologies able to convert abundant and sustainable resources into sustainable aviation fuels in a cost-effective manner is a priority. The HIGFLY project addresses EU priorities through the development of high performance technologies and their integration in EU's energy system, by reducing the cost of key technologies through maximizing resource and energy efficiency and by strengthening market uptake through intensive early-stage cooperation of experts along the entire value chain.
The overall objective of HIGFLY is to develop and demonstrate at TRL 3-4 novel technologies for the production of advanced bio jet fuel from abundant and sustainable biomass feedstocks. To that end, HIGFLLY aims at
- Converting under-utilized hemicellulose fraction and equivalent carbohydrates in other biomasses and biorefinery streams, HIGLY keeps at its core important elements towards future deployment: feedstock flexibility, synergies across the bioenergy sector, and technical developments towards technology scalability.
- Developing innovative, highly-efficient and robust reactor and separation technologies to produce advanced bio jet fuels in a resource, energy and cost-effective manner.
- Developing new and robust catalytic materials and sustainable solvents for the renewable energy sector.
- Advancing the knowledge of its innovative technologies through evaluation of the entire value chain, from feedstock(s) to bio jet fuel, to demonstrate the advantages of the environmental, social and techno-economic performance of HIGFLY technologies and the prospect of regulatory compliance of HIGFLY’s bio jet fuel.
The overall objective of HIGFLY is to develop and demonstrate at TRL 3-4 novel technologies for the production of advanced bio jet fuel from abundant and sustainable biomass feedstocks. To that end, HIGFLLY aims at
- Converting under-utilized hemicellulose fraction and equivalent carbohydrates in other biomasses and biorefinery streams, HIGLY keeps at its core important elements towards future deployment: feedstock flexibility, synergies across the bioenergy sector, and technical developments towards technology scalability.
- Developing innovative, highly-efficient and robust reactor and separation technologies to produce advanced bio jet fuels in a resource, energy and cost-effective manner.
- Developing new and robust catalytic materials and sustainable solvents for the renewable energy sector.
- Advancing the knowledge of its innovative technologies through evaluation of the entire value chain, from feedstock(s) to bio jet fuel, to demonstrate the advantages of the environmental, social and techno-economic performance of HIGFLY technologies and the prospect of regulatory compliance of HIGFLY’s bio jet fuel.
The concept developed at HIGFLY for jet fuel synthesis focuses on the use of furfural as main intermediate to yield a variety of hydrocarbons in the jet fuel range. Thus, the main work in RP1 is summarized below:
In WP2, a two-step strategy for the synthesis of furfural (first step) and derivatives (second step) has been investigated. Among the two, the first step constitutes the bottleneck of the entire process and is therefore the primary focus of research. More than 35 solid acid catalyst have been synthesized, characterized and tested, and two promising candidates have identified for further studies. They present competitive product yields, and do not show signs of deactivation. The basis of a kinetic model has been established, and numerical reactor model was built for reactor design purposes. Several methods for coating the new developed materials on 3D structures have been optimized. These new materials have been used for processing of real hemicellulose streams in continuous reactors, with no significant deactivation after 10s of hours of time on stream. These structured catalysts will be use in a HiGee reactor, which has has been designed and is currently being prepared for operation. Tests will start soon. Another key element in HIGFLY is the use of new Deep-Eutectic Solvents (DESs). Among the already reported DESs, a few potential candidates have been identified and tested in the process, showing promising results in combination with the new catalysts developed in the project. Further, a highly advanced AI-based predictive model has been developed for the discovery of new solvents. A completely new solvent with very promising properties is currently being studied.
In WP3, basic catalysts for the condensation of furfural with ketones have been selected and formed structures of these catalysts (pellet or extrudate) have been produced. Two process routes for the condensation of furfural and ketones have been explored: low temperature/liquid phase and high temperature/gas phase. The condensation at low temperature has been translated from batch to continuous using a commercial Al-Mg hydrotalcite, providing 50 h stable operation and high yields of target condensation products. Two of the selected catalysts have been tested under these conditions with diverse product distribution, stability and activity. The condensation process in the gas phase at high temperature has been performed with a commercial basic doped activated carbon catalyst. Besides, an alternative approach for the high temperature process is being explored, where cyclopentanone as produced in WP2 can be used in combination with other biobased alcohols. Furthermore, a variety of Nickel and Platinum Group Metal catalysts were screened for the hydrotreatment of condensed molecules produced from the aforementioned process routes. A few samples of jet fuels were produced, and will be further analyzed in the next period.
The suitability and sustainability of jet fuels derived from furfural and bio-oxygenates is assessed in WP5. The main work of this work package in focused on the following tasks. In the first task, we compiled an inventory of the biorefinery concepts that possibly could be integrated with the HIGFLY process. We analyzed the platform/C5 sugars according to their composition required and derived conclusions on the requirements for the pre-treatment process and the biomass feedstocks. We also looked at the availability of different biomass feedstock options. The second task focused on the conceptual process design, modelling and TEE. Finally, the third task in is a sustainability assessment, which is currently ongoing. In the next period, insights on fuel quality and prospects of regulatory compliance will be further analyzed.
In WP2, a two-step strategy for the synthesis of furfural (first step) and derivatives (second step) has been investigated. Among the two, the first step constitutes the bottleneck of the entire process and is therefore the primary focus of research. More than 35 solid acid catalyst have been synthesized, characterized and tested, and two promising candidates have identified for further studies. They present competitive product yields, and do not show signs of deactivation. The basis of a kinetic model has been established, and numerical reactor model was built for reactor design purposes. Several methods for coating the new developed materials on 3D structures have been optimized. These new materials have been used for processing of real hemicellulose streams in continuous reactors, with no significant deactivation after 10s of hours of time on stream. These structured catalysts will be use in a HiGee reactor, which has has been designed and is currently being prepared for operation. Tests will start soon. Another key element in HIGFLY is the use of new Deep-Eutectic Solvents (DESs). Among the already reported DESs, a few potential candidates have been identified and tested in the process, showing promising results in combination with the new catalysts developed in the project. Further, a highly advanced AI-based predictive model has been developed for the discovery of new solvents. A completely new solvent with very promising properties is currently being studied.
In WP3, basic catalysts for the condensation of furfural with ketones have been selected and formed structures of these catalysts (pellet or extrudate) have been produced. Two process routes for the condensation of furfural and ketones have been explored: low temperature/liquid phase and high temperature/gas phase. The condensation at low temperature has been translated from batch to continuous using a commercial Al-Mg hydrotalcite, providing 50 h stable operation and high yields of target condensation products. Two of the selected catalysts have been tested under these conditions with diverse product distribution, stability and activity. The condensation process in the gas phase at high temperature has been performed with a commercial basic doped activated carbon catalyst. Besides, an alternative approach for the high temperature process is being explored, where cyclopentanone as produced in WP2 can be used in combination with other biobased alcohols. Furthermore, a variety of Nickel and Platinum Group Metal catalysts were screened for the hydrotreatment of condensed molecules produced from the aforementioned process routes. A few samples of jet fuels were produced, and will be further analyzed in the next period.
The suitability and sustainability of jet fuels derived from furfural and bio-oxygenates is assessed in WP5. The main work of this work package in focused on the following tasks. In the first task, we compiled an inventory of the biorefinery concepts that possibly could be integrated with the HIGFLY process. We analyzed the platform/C5 sugars according to their composition required and derived conclusions on the requirements for the pre-treatment process and the biomass feedstocks. We also looked at the availability of different biomass feedstock options. The second task focused on the conceptual process design, modelling and TEE. Finally, the third task in is a sustainability assessment, which is currently ongoing. In the next period, insights on fuel quality and prospects of regulatory compliance will be further analyzed.
HIGFLY will progress beyond the state of the art by developing & demonstrating at TRL 3-4:
- A new route for the conversion of sustainable and abundant feedstocks to sustainable aviation fuel with higher carbon efficiency than the existing routes.
- New solid catalysts, green solvents and intensified reactors for the synthesis of furfural and bio-oxygenates that will synergistically extend product recovery beyond the state-of-the-art (potentially up to >90% carbon efficiency), preventing solid deposits, allowing for continuous (scalable) operation and minimizing solvent use.
- Novel supported liquid membranes for the purification of bio-oxygenates with reduced energy requirements.
- Scalable and efficient catalytic technologies for the condensation of furfural and bio-oxygenates with > 80% yield within continuous operation and towards future scaleup.
- Several routes for the valorization of side-streams to maximize resource & energy efficiency.
HIGFLY has the potential to:
- Produce advanced bio fuels for the aviation sector (bio-based jet fuels) from abundant and sustainable biomass feedstocks.
- Increase biomass conversion efficiency to advanced bio fuels by increase of carbon efficiency of the most challenging synthesis step.
- Reduce costs of next generation advanced bio fuels by ca. 25% through increase of resource and energy of efficiency.
- Decrease emissions equivalent to ca. 20% of aviation-based GHGs in EU (based on 800 PJ bio jet fuel generation).
- Accelerate commercialization of next generation of advanced bio fuels for the aviation sector by developing highly efficient and robust technologies for the scalable production of advanced bio fuels in EU over a period of 10 years.
- Contribute to establishing EU leadership position with respect to implementation of renewable energies in the aviation sector.
- A new route for the conversion of sustainable and abundant feedstocks to sustainable aviation fuel with higher carbon efficiency than the existing routes.
- New solid catalysts, green solvents and intensified reactors for the synthesis of furfural and bio-oxygenates that will synergistically extend product recovery beyond the state-of-the-art (potentially up to >90% carbon efficiency), preventing solid deposits, allowing for continuous (scalable) operation and minimizing solvent use.
- Novel supported liquid membranes for the purification of bio-oxygenates with reduced energy requirements.
- Scalable and efficient catalytic technologies for the condensation of furfural and bio-oxygenates with > 80% yield within continuous operation and towards future scaleup.
- Several routes for the valorization of side-streams to maximize resource & energy efficiency.
HIGFLY has the potential to:
- Produce advanced bio fuels for the aviation sector (bio-based jet fuels) from abundant and sustainable biomass feedstocks.
- Increase biomass conversion efficiency to advanced bio fuels by increase of carbon efficiency of the most challenging synthesis step.
- Reduce costs of next generation advanced bio fuels by ca. 25% through increase of resource and energy of efficiency.
- Decrease emissions equivalent to ca. 20% of aviation-based GHGs in EU (based on 800 PJ bio jet fuel generation).
- Accelerate commercialization of next generation of advanced bio fuels for the aviation sector by developing highly efficient and robust technologies for the scalable production of advanced bio fuels in EU over a period of 10 years.
- Contribute to establishing EU leadership position with respect to implementation of renewable energies in the aviation sector.