Work Package 1: Realization of a HP-MEA electrolyzer demonstrator
The aim of the first WP of HIPECO2 was to fabricate a custom-made HP-membrane electrode assembly (MEA) electrolyzer that will be used as a prototype to optimize our technology for the production of ethylene.we successfully designed and constructed a high-pressure electrolyzer demonstrator tailored for CO2 electrolysis under elevated pressures. The design was elaborated in collaboration with the internal machine shop of our institute (Figure 1). This pilot demonstrator allowed us to investigate the electrochemical reduction of CO2 at pressures significantly higher than atmospheric, enhancing the reaction kinetics and potentially increasing the efficiency and selectivity of CO2 conversion processes.
Work Package 2: Testing functionalized Cu-based electrodes in the flow reactor
The pilot has been commissioned and tested for the conversion of CO2. We have notably explored the following parameters:
- The type of polymer electrolyte membranes
- The effect of pressure on the performance
- The stability of the electrolysis performance
Work Package 3: Estimation of the CAPEX and OPEX costs
Because the current performance of the Cu catalysts in the high pressure electrolyzer is unsatisfactory, we decided to solely perform the estimation of the OPEX using our optimal performance using electrodeposited copper, reported in early 2024 (Nature Energy, 2024, 9, 422–433 [DOI:10.1038/s41560-024-01461-6]). We used two model catalyst: Cu and Cu-NN where NN represent an organic molecules attached on the surface of the Cu catalyst to enhance the selectivity for ethylene.
To assess the economic viability of electro-reduction of CO2 to C2H4 on Cu, Cu-NN, we carried out techno-economic analyses by comparing the direct conversion route (CO2-to-C2H4 in a single reactor) with the two steps cascade systems (CO2-to-CO, and CO-to-C2H4 in cascade system). We determined the OPEX of the direct and the cascade flow processes for the production of 1 ton of C2H4. In our calculations, we assumed a catalyst lifetime of one year (8,760 hours) and a total electrode surface of 100 m2. Figure 2 show the cost distribution for the different parameters, without considering the CO2 loss due to carbonate formation and membrane crossover as well as the downstream separation costs. Among the four different MEA configurations, we found that direct conversion of CO2 to ethylene using Cu-NN is the closest to profitability. Importantly the cost of ethylene production decreases from 12,600 $ ton-1 to 4,500 $ ton-1 using pristine Cu (dashed line) and Cu-NN (solid line), respectively, which corresponds to a 64% reduction.
Work Package 4: Outreaching partners and presenting the technology at professional congress and forum
Primary task included engaging directly with key stakeholders from potential customers to industry experts. We have conducted interviews, surveys, and focused group discussions to gain in-depth insights into the industry's needs, challenges, and potential opportunities. These discussions provided invaluable feedback regarding the solution's perceived value, potential applications, and the hurdles we might face in its implementation. The secondary research consisted of reviewing extensive literature, market reports, and public databases to obtain a macro-level understanding of the ethylene market. We also analysed market growth projections, key demand drivers, and emerging technological trends. Through these explorations, we has gained a robust understanding of the market potential and acceptability of the e-ethylene solution, which forms the foundation for future market strategy and product development.
