Periodic Reporting for period 1 - ECO2Fuel (LARGE-SCALE LOW-TEMPERATURE ELECTROCHEMICAL CO2 CONVERSION TO SUSTAINABLE LIQUID FUELS)
Reporting period: 2021-10-01 to 2023-03-31
The ECO2Fuel project is an initiative under the European Union's Horizon2020 (Green Deal) that aims to address the pressing issue of climate change by revolutionizing the way we source carbon. The project is focused on the development, operation, and validation of the world's first low-temperature 1MW direct, electrochemical CO2 conversion system. This system is designed to produce economically viable and sustainable liquid e-fuels and chemicals.
The problem being addressed by the ECO2Fuel project is the over-reliance on fossil fuels as the primary source of carbon. This reliance is responsible for the emission of CO2, which accelerates climate change. The project seeks to change this paradigm by deriving carbon from CO2 instead of fossil fuels. This approach will help to reduce emissions from thousands of essential items, set new standards for the industry, and prevent further CO2 emissions.
The importance of this project for society is immense. Carbon is a fundamental component of life and drives innovations in various sectors, including fuel, electronics, building materials, and electric car parts. By replacing fossil carbon in fuels and chemicals with recycled carbon from CO2, the project can contribute significantly to reducing the carbon footprint of these sectors. This is particularly crucial as the demand for transport, which accounts for around a fifth of global CO2 emissions, is expected to grow worldwide in the coming decades.
The overall objectives of the ECO2Fuel project are multifaceted. Firstly, it aims to scale a single-step CO2 conversion process to produce liquid e-fuels without the need for hydrogen. Secondly, the project is not only about recycling carbon from CO2 but also about the smart development, scale-up, implementation, and recycling of the critical components and the optimized use of the produced fuels and chemicals. Lastly, the project represents a unique opportunity to bring the CO2 electrochemical reduction technology to an industrial relevant level, which is a powerful route to achieve an important milestone towards a greener future.
The ECO2Fuel project is a collaborative effort involving an international consortium from Germany, Italy, Spain, Belgium, Denmark, Israel, Greece, and the Netherlands. These partners are committed to driving the electrochemical carbon dioxide reduction towards commercialization in the next five years, thereby assuring the leading position of the EU in developing green technologies for a brighter future.
The problem being addressed by the ECO2Fuel project is the over-reliance on fossil fuels as the primary source of carbon. This reliance is responsible for the emission of CO2, which accelerates climate change. The project seeks to change this paradigm by deriving carbon from CO2 instead of fossil fuels. This approach will help to reduce emissions from thousands of essential items, set new standards for the industry, and prevent further CO2 emissions.
The importance of this project for society is immense. Carbon is a fundamental component of life and drives innovations in various sectors, including fuel, electronics, building materials, and electric car parts. By replacing fossil carbon in fuels and chemicals with recycled carbon from CO2, the project can contribute significantly to reducing the carbon footprint of these sectors. This is particularly crucial as the demand for transport, which accounts for around a fifth of global CO2 emissions, is expected to grow worldwide in the coming decades.
The overall objectives of the ECO2Fuel project are multifaceted. Firstly, it aims to scale a single-step CO2 conversion process to produce liquid e-fuels without the need for hydrogen. Secondly, the project is not only about recycling carbon from CO2 but also about the smart development, scale-up, implementation, and recycling of the critical components and the optimized use of the produced fuels and chemicals. Lastly, the project represents a unique opportunity to bring the CO2 electrochemical reduction technology to an industrial relevant level, which is a powerful route to achieve an important milestone towards a greener future.
The ECO2Fuel project is a collaborative effort involving an international consortium from Germany, Italy, Spain, Belgium, Denmark, Israel, Greece, and the Netherlands. These partners are committed to driving the electrochemical carbon dioxide reduction towards commercialization in the next five years, thereby assuring the leading position of the EU in developing green technologies for a brighter future.
(WP1) A system for successful technical and administrative coordination was established, and an efficient communication strategy was set up for internal dialogue and correspondence with the EC. An ever-evolving management handbook was also prepared, outlining the strategies for innovation management, risk mitigation, and comprehensive work documentation.
(WP2) With the foundational specifications established, the design process for the pilot plant's system and the demonstrator began. The pilot plant stack's design was made scalable, making it suitable for its translation into the final demonstrator stack size. The components required for the pilot plant system have been ordered.
(WP3) the Oxygen Evolution Reaction (OER) and Carbon Dioxide Reduction Reaction (CO2RR) catalysts underwent a screening process. Synthesis routes were optimized with scalability in mind, leading to the production of the most promising candidates at a semi-pilot scale. Pilot-scale catalyst synthesis has begun to ensure a steady material supply for pilot production.
(WP4) The project has completed the first phase of membrane development, resulting in the final GEN2 membranes and ionomers. Membrane and ionomer characterizations are well advanced and are nearing completion. Tests for ionomer solubility, ions, alcohols, hydrogen and carbon dioxide crossover are also in progress.
(WP5) Catalyst inks with suitable rheological properties were defined, yielding highly active and mechanically stable high surface area electrodes with an optimized porous fibre structure. Single cell tests, with the project electrode, membrane and ionomers, are continually conducted, with the used Membrane Electrode Assemblies (MEAs) being subjected to recycling studies.
(WP6) Work Package 6 has yet to commence.
(WP7) Work on permitting and site preparation for the 1MW demonstrator, including preparation of the installation area and connections to site utilities and the control room, has begun.
(WP8) The project has progressed with fuel specification through an extensive literature study and initial synthesis and testing of alcohol-diesel blends. Fuel validation work in GenSets was conducted, including the adaptation of the GenSet to diesel fuel, and the system passed the Factory Acceptance Test in June 2023.
(WP9) The project started on a technical, economic, environmental, and social analysis supported by multiple questionnaires and a workshop. Concurrently, a market study focusing on upstream steps and benchmark systems for the defined use cases was initiated.
(WP10) a project identity was created, along with a website and social media accounts. A Communication & Dissemination (C&D) strategy was developed, and stakeholder analysis started, resulting in a stakeholder list. Key exploitable results were identified in an exploitation workshop.
(WP2) With the foundational specifications established, the design process for the pilot plant's system and the demonstrator began. The pilot plant stack's design was made scalable, making it suitable for its translation into the final demonstrator stack size. The components required for the pilot plant system have been ordered.
(WP3) the Oxygen Evolution Reaction (OER) and Carbon Dioxide Reduction Reaction (CO2RR) catalysts underwent a screening process. Synthesis routes were optimized with scalability in mind, leading to the production of the most promising candidates at a semi-pilot scale. Pilot-scale catalyst synthesis has begun to ensure a steady material supply for pilot production.
(WP4) The project has completed the first phase of membrane development, resulting in the final GEN2 membranes and ionomers. Membrane and ionomer characterizations are well advanced and are nearing completion. Tests for ionomer solubility, ions, alcohols, hydrogen and carbon dioxide crossover are also in progress.
(WP5) Catalyst inks with suitable rheological properties were defined, yielding highly active and mechanically stable high surface area electrodes with an optimized porous fibre structure. Single cell tests, with the project electrode, membrane and ionomers, are continually conducted, with the used Membrane Electrode Assemblies (MEAs) being subjected to recycling studies.
(WP6) Work Package 6 has yet to commence.
(WP7) Work on permitting and site preparation for the 1MW demonstrator, including preparation of the installation area and connections to site utilities and the control room, has begun.
(WP8) The project has progressed with fuel specification through an extensive literature study and initial synthesis and testing of alcohol-diesel blends. Fuel validation work in GenSets was conducted, including the adaptation of the GenSet to diesel fuel, and the system passed the Factory Acceptance Test in June 2023.
(WP9) The project started on a technical, economic, environmental, and social analysis supported by multiple questionnaires and a workshop. Concurrently, a market study focusing on upstream steps and benchmark systems for the defined use cases was initiated.
(WP10) a project identity was created, along with a website and social media accounts. A Communication & Dissemination (C&D) strategy was developed, and stakeholder analysis started, resulting in a stakeholder list. Key exploitable results were identified in an exploitation workshop.
Progress Beyond the State of the Art:
The project has made a significant leap from state-of-the-art CO2 electrolysis, which typically yields low-value products like CO or formic acid, by building on a 5kW system from the LOTER.CO2M project. The advancement to a 50 kW system, currently under construction at VITO, represents a substantial upscaling in terms of materials, components, and system size.
The development of novel materials and components for a CO2 electrolyser at this scale (50kW) surpasses current state-of-the-art technologies, which are mostly confined to lab-scale demonstrations with low active surface areas and power not exceeding 1kW.
Expected Results:
The project's immediate focus is on testing the prototype and further upscaling the design for the large-scale 1MW demonstrator.
Essential site preparation and permitting documentation for the 1 MW ECO2Fuel demonstrator has been completed, which is crucial for the permitting authorities and the activities of the project partners on the industrial demonstration site.
The project is also gearing up to validate climate-friendly peak-power production with multiple carbon recycling, with construction work for integrating the peak-power generator into the industrial site's infrastructure underway and validation tests scheduled to start in Q2 2024.
Potential Impacts:
The project anticipates generating exploitable results that will offer options for peak power production from carbonaceous fuels with ultra-low CO2 emissions, potentially leading to significant benefits in terms of carbon footprint emission mitigation, energy efficiency, and the development of licenses.
Socio-economic and wider societal implications are a major focus, with the project aiming to validate the economic feasibility of the ECO2Fuel technology through a techno-economic analysis and achieve a substantial reduction in industrial CO2 emissions, targeting at least 200 Mt per annum by 2050 and maintaining a carbon intensity below 20 g CO2eq/MJ, as assessed using life cycle assessment.
The project has made a significant leap from state-of-the-art CO2 electrolysis, which typically yields low-value products like CO or formic acid, by building on a 5kW system from the LOTER.CO2M project. The advancement to a 50 kW system, currently under construction at VITO, represents a substantial upscaling in terms of materials, components, and system size.
The development of novel materials and components for a CO2 electrolyser at this scale (50kW) surpasses current state-of-the-art technologies, which are mostly confined to lab-scale demonstrations with low active surface areas and power not exceeding 1kW.
Expected Results:
The project's immediate focus is on testing the prototype and further upscaling the design for the large-scale 1MW demonstrator.
Essential site preparation and permitting documentation for the 1 MW ECO2Fuel demonstrator has been completed, which is crucial for the permitting authorities and the activities of the project partners on the industrial demonstration site.
The project is also gearing up to validate climate-friendly peak-power production with multiple carbon recycling, with construction work for integrating the peak-power generator into the industrial site's infrastructure underway and validation tests scheduled to start in Q2 2024.
Potential Impacts:
The project anticipates generating exploitable results that will offer options for peak power production from carbonaceous fuels with ultra-low CO2 emissions, potentially leading to significant benefits in terms of carbon footprint emission mitigation, energy efficiency, and the development of licenses.
Socio-economic and wider societal implications are a major focus, with the project aiming to validate the economic feasibility of the ECO2Fuel technology through a techno-economic analysis and achieve a substantial reduction in industrial CO2 emissions, targeting at least 200 Mt per annum by 2050 and maintaining a carbon intensity below 20 g CO2eq/MJ, as assessed using life cycle assessment.