Periodic Reporting for period 1 - 4AirCRAFT (Air Carbon Recycling for Aviation Fuel Technology)
Período documentado: 2021-05-01 hasta 2022-10-31
Aviation is a capital-intensive industry characterised by a high-dependence on a global supply of energy-dense fuels, greenhouse gas emissions due to aviation industry account for 13 % of the emissions for transport emitting more than 900 million tons of CO2 per year.
The background technology for producing petrol, kerosene or heavy fuels use fossil carbon sources and high temperatures and therefore new technologies and further innovation are required for (i) enabling carbon dioxide to be employed as the carbon source at the starting point of the production process, and (ii) minimising the energy consumption of the process.
This can be achieved by finding new catalysts able to reduce the energy barriers of the key steps within the reaction chain. An even greener and more challenging alternative is to produce fuels for aviation starting from their fundamental components: CO2 and H2.
The main goal of this project is the process intensification by a single cascade reactor and the synthesis at mild conditions of alternative high-density fuels from CO2, to ultimately lead aviation industry to a sustainable future.
By the rational design of each material (nano-catalysts, bioinspired catalysts, electrocatalyst, MOF, and hierarchically porous inorganic carriers), their synergetic combination, and the fine-tuning of each “catalytic environment” in a holistic manner, the temperature needed for the production of long-chain hydrocarbons will be reduced as compared to current processes.
This goal will be achieved by combining the target reactions into a single cascade reactor without purification steps, while reducing energy consumption, thereby making the whole process more cost and energy efficient.
Thus, 4AirCRAFT will proof a new concept for the production of clean and sustainable liquid fuels. The unique and energy-efficient cascade reactor technology will convert precisely and efficiently CO2 into C8-C16 hydrocarbons.
The background technology for producing petrol, kerosene or heavy fuels use fossil carbon sources and high temperatures and therefore new technologies and further innovation are required for (i) enabling carbon dioxide to be employed as the carbon source at the starting point of the production process, and (ii) minimising the energy consumption of the process.
This can be achieved by finding new catalysts able to reduce the energy barriers of the key steps within the reaction chain. An even greener and more challenging alternative is to produce fuels for aviation starting from their fundamental components: CO2 and H2.
The main goal of this project is the process intensification by a single cascade reactor and the synthesis at mild conditions of alternative high-density fuels from CO2, to ultimately lead aviation industry to a sustainable future.
By the rational design of each material (nano-catalysts, bioinspired catalysts, electrocatalyst, MOF, and hierarchically porous inorganic carriers), their synergetic combination, and the fine-tuning of each “catalytic environment” in a holistic manner, the temperature needed for the production of long-chain hydrocarbons will be reduced as compared to current processes.
This goal will be achieved by combining the target reactions into a single cascade reactor without purification steps, while reducing energy consumption, thereby making the whole process more cost and energy efficient.
Thus, 4AirCRAFT will proof a new concept for the production of clean and sustainable liquid fuels. The unique and energy-efficient cascade reactor technology will convert precisely and efficiently CO2 into C8-C16 hydrocarbons.
Recently, renewable energies, such as solar and wind power, have been installed as electricity power sources, while its extensive installation generates surplus electricity. Thus, the surplus electricity can be used for a conversion of CO2 into molecules for direct use in liquid fuel.
During the first half of the project, we have developed a novel catalyst for CO2 conversion that contains only non-precious elements.
Currently, the selectivity and efficiency of the conversion of the novel catalyst is being improved by chemical modification and exploring the combination of supports and catalyst to reach the target value.
We have also performed the synthesis of several inorganic nanocatalysts for the conversion of CO to hydrocarbons. After the synthesis and initial characterization, catalytic testing and screening has been performed. Our results show CO conversion however, further investigations are focused on reaching milder synthesis conditions than current ones. Selectivity to aviation fuels has not been achieved yet, which indicates that further optimization of the catalysts is required.
XRD, TGA, volumetry and in situ IR spectroscopy were employed to gain a deeper understanding into the catalytic properties of the different catalysts.
HRTEM, EDX and electron diffraction gave a view of the microstructure of the LDH (basal spacing, homogeneity, defects).
Various types of biocatalysts and biomimetic catalysts were screened for the organic-synthetic dehydration target reaction, and most promising catalysts have been prioritized. We could demonstrate that with the most suitable catalytic systems, dehydration can be conducted under mild reaction conditions and furnished the desired alkene products in good yield. Process optimization of this key step are currently ongoing.
HRTEM, EDX and electron diffraction gave a view of the microstructure of MOF (morphology and preliminary enzyme distribution).
Regarding the biocatalysts´ encapsulation into porous MOFs, the synthesis conditions of tetravalent metal-based MOFs have been softened down to room temperature. Overall, this synthesis protocol has allowed to achieve the first efficient encapsulation of a model enzyme into the material during its crystallization. In return, the activity of the enzyme once immobilized is partially affected in comparison to the one of the free biocatalysts. Alternative biomimetic systems are being developed as a mitigation plan to obtain a system able to work efficiently at mild conditions.
In case of inorganic supports manufacturing, supports for functionalization with MOF`s
and supports with lamellar porosity features for electrocatalysts have been developed.
Structural components for the cascade reactor have been preliminary designed and are subjected to optimization through the findings from their performance.
A plan for Communication, Dissemination and Awareness and a plan for Exploitation were developed. A project website has been developed (www.4aircraft-project.eu). The External Advisory Board has been engaged representing some of the world’s leading industries on sustainable fuels production for transport and petrochemical use as well as sustainable feedstock for specialty chemicals and other purposes among others.
During the first half of the project, we have developed a novel catalyst for CO2 conversion that contains only non-precious elements.
Currently, the selectivity and efficiency of the conversion of the novel catalyst is being improved by chemical modification and exploring the combination of supports and catalyst to reach the target value.
We have also performed the synthesis of several inorganic nanocatalysts for the conversion of CO to hydrocarbons. After the synthesis and initial characterization, catalytic testing and screening has been performed. Our results show CO conversion however, further investigations are focused on reaching milder synthesis conditions than current ones. Selectivity to aviation fuels has not been achieved yet, which indicates that further optimization of the catalysts is required.
XRD, TGA, volumetry and in situ IR spectroscopy were employed to gain a deeper understanding into the catalytic properties of the different catalysts.
HRTEM, EDX and electron diffraction gave a view of the microstructure of the LDH (basal spacing, homogeneity, defects).
Various types of biocatalysts and biomimetic catalysts were screened for the organic-synthetic dehydration target reaction, and most promising catalysts have been prioritized. We could demonstrate that with the most suitable catalytic systems, dehydration can be conducted under mild reaction conditions and furnished the desired alkene products in good yield. Process optimization of this key step are currently ongoing.
HRTEM, EDX and electron diffraction gave a view of the microstructure of MOF (morphology and preliminary enzyme distribution).
Regarding the biocatalysts´ encapsulation into porous MOFs, the synthesis conditions of tetravalent metal-based MOFs have been softened down to room temperature. Overall, this synthesis protocol has allowed to achieve the first efficient encapsulation of a model enzyme into the material during its crystallization. In return, the activity of the enzyme once immobilized is partially affected in comparison to the one of the free biocatalysts. Alternative biomimetic systems are being developed as a mitigation plan to obtain a system able to work efficiently at mild conditions.
In case of inorganic supports manufacturing, supports for functionalization with MOF`s
and supports with lamellar porosity features for electrocatalysts have been developed.
Structural components for the cascade reactor have been preliminary designed and are subjected to optimization through the findings from their performance.
A plan for Communication, Dissemination and Awareness and a plan for Exploitation were developed. A project website has been developed (www.4aircraft-project.eu). The External Advisory Board has been engaged representing some of the world’s leading industries on sustainable fuels production for transport and petrochemical use as well as sustainable feedstock for specialty chemicals and other purposes among others.
At the core of 4AirCRAFT innovation is the synergetic combination of tailor-made electro-, chemo- and bioinspired catalysts and their controlled spatial distribution within application tuned catalysts carrier structures. This will enhance the activity of catalytic phases and materials allowing high CO2 conversion rates and selectivity towards jet fuels.
The conversion of CO into aviation fuels under mild reaction conditions, such as below 250 °C would already represent an achievement beyond the state-of-the-art. This would already represent massive economic and environmental impacts in the aviation industry and thus on society.
A promising catalytic dehydration methodology leading to the desired alkene products (which serves as key intermediates for the envisaged jet fuels) has been developed in the first phase of this project. Based on this progress, we will now further focus on optimization and process intensification of this technology, which is expected to be a “ready-to-use”-technology for technical purpose at the end of the project. In case of success, this technology will be also usable for other related industrial alkene products, thus then representing a “technology platform” with applications also in the other segments of the chemical industry, in particular for the fields of bulk and specialty chemicals.
This is the first time that an enzyme encapsulation is achieved in chemically robust MOFs. Further optimization of the process can give rise to a robust biocatalyst-based system able to work under non-conventional conditions usually employed for enzymes. If this point is reached, the techno-economic impact of the result could gain the interests of petrochemical and pharmaceutical industries.
This unique process would require much less energy, potentially reducing the cost of sustainable fuel for the aviation sector.
The environmental benefits of alternative fuels for aviation are further enhanced by capturing atmospheric carbon originating from various sources such as biomasses, industrial processes, and from direct capture from air.
The conversion of CO into aviation fuels under mild reaction conditions, such as below 250 °C would already represent an achievement beyond the state-of-the-art. This would already represent massive economic and environmental impacts in the aviation industry and thus on society.
A promising catalytic dehydration methodology leading to the desired alkene products (which serves as key intermediates for the envisaged jet fuels) has been developed in the first phase of this project. Based on this progress, we will now further focus on optimization and process intensification of this technology, which is expected to be a “ready-to-use”-technology for technical purpose at the end of the project. In case of success, this technology will be also usable for other related industrial alkene products, thus then representing a “technology platform” with applications also in the other segments of the chemical industry, in particular for the fields of bulk and specialty chemicals.
This is the first time that an enzyme encapsulation is achieved in chemically robust MOFs. Further optimization of the process can give rise to a robust biocatalyst-based system able to work under non-conventional conditions usually employed for enzymes. If this point is reached, the techno-economic impact of the result could gain the interests of petrochemical and pharmaceutical industries.
This unique process would require much less energy, potentially reducing the cost of sustainable fuel for the aviation sector.
The environmental benefits of alternative fuels for aviation are further enhanced by capturing atmospheric carbon originating from various sources such as biomasses, industrial processes, and from direct capture from air.