Periodic Reporting for period 1 - HIPECO2 (Membrane Electrode Assembly for the High Pressure Electrochemical Conversion of CO2 to C2H4)
Berichtszeitraum: 2022-09-01 bis 2024-04-30
According to the most recent report from the Intergovernmental Panel on Climate Change (IPCC), the rapid increase of the CO2 concentration in the atmosphere has direct environmental and societal consequences1. The Paris Agreement has set the goal of maintaining the temperature increase to 1.5°C, well below a more realistic – yet challenging – limit of 2°C. In this context the European Union (EU) has signed the Europe Green Deal with the ambition to be climate neutral by 20503, which imposes a 55 % decrease of the CO2 emission by 2030 compared to those of 1990. The EU must therefore implement new sets of policies to trigger a paradigm shift from the carbon economy towards the development of a climate neutral economy.
Ethylene (C2H4) plays a major role in the chemical industry and is ranked #2 chemicals based on the volume. Its global production has reached around 160 million metric tons, with a market value of 202 billion US dollars (185 billion euros), and is set to increase by more than 10% between 2018 and 2023. However, the current production method, based on steam cracking of naphtha or natural gas, contributes to around 240 million metric tons of CO2 emissions per year (or 0.7% of total CO2 emissions).
Based on the initial results obtained during the ERC-StG 2D4CO2, the ERC-POC HIPECO2 aimed to explore the potential of the technology for pratical application. The specific goals of this project were to:
1) Fabricate and test a HP-MEA electrolyzer demonstrator that achieve performance metrics compatible with the industrial requirements in term of current density, electrical power consumption (EPC) and stability.
2) Develop a business model of our technology and reach out partners to prepare the launch of a spin-off company based on the HIPECO2 outcomes.
Ethylene (C2H4) plays a major role in the chemical industry and is ranked #2 chemicals based on the volume. Its global production has reached around 160 million metric tons, with a market value of 202 billion US dollars (185 billion euros), and is set to increase by more than 10% between 2018 and 2023. However, the current production method, based on steam cracking of naphtha or natural gas, contributes to around 240 million metric tons of CO2 emissions per year (or 0.7% of total CO2 emissions).
Based on the initial results obtained during the ERC-StG 2D4CO2, the ERC-POC HIPECO2 aimed to explore the potential of the technology for pratical application. The specific goals of this project were to:
1) Fabricate and test a HP-MEA electrolyzer demonstrator that achieve performance metrics compatible with the industrial requirements in term of current density, electrical power consumption (EPC) and stability.
2) Develop a business model of our technology and reach out partners to prepare the launch of a spin-off company based on the HIPECO2 outcomes.
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.
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.
The ERC-POC project HIPECO2 has made significant progress in advancing CO2 electrolysis technology, with a strong focus on upscaling and optimizing the process for industrial application. By developing and implementing a pilot demonstrator of a high-pressure CO2 electrolyzer, the project demonstrated the potential for enhanced efficiency and selectivity in CO2 conversion, particularly towards valuable multicarbon products like ethylene. Additionally, the adoption of a new cathode fabrication process using colloidal catalysts has improved the reproducibility and reduced the costs of Cu electrode production, enabling the creation of larger (up to 100 cm2), more uniform electrodes.
Despite the challenges encountered, such as limited improvements in ethylene selectivity under high pressure, the project has laid the groundwork for further innovations in catalyst design and membrane-electrode assembly optimization. The discussion with partners has also facilitated the transition of this technology from the lab to potential real-world applications, positioning it as a viable solution for CO2 utilization and contributing to the development of a circular carbon economy.
The project has also enabled to make decisive advance in developing the business models. Our discussion with potentials stakeholders has convinced Damien Voiry about the potential of the emerging technology. One of the outcome of HIPECO2 has been the foundation of the startup E-ETHYLENE to develop and commercialize industrial CO2 electrolyzer in August 2023. E-ETHYLENE has established a comprehensive roadmap to commercialize industrial-scale CO2 electrolyzers by 2031. The company is currently seeking funding opportunities, such as through the i-LAB or EIC Transition schemes, and is actively pursuing partnerships with both private and public stakeholders to accelerate this initiative.
Despite the challenges encountered, such as limited improvements in ethylene selectivity under high pressure, the project has laid the groundwork for further innovations in catalyst design and membrane-electrode assembly optimization. The discussion with partners has also facilitated the transition of this technology from the lab to potential real-world applications, positioning it as a viable solution for CO2 utilization and contributing to the development of a circular carbon economy.
The project has also enabled to make decisive advance in developing the business models. Our discussion with potentials stakeholders has convinced Damien Voiry about the potential of the emerging technology. One of the outcome of HIPECO2 has been the foundation of the startup E-ETHYLENE to develop and commercialize industrial CO2 electrolyzer in August 2023. E-ETHYLENE has established a comprehensive roadmap to commercialize industrial-scale CO2 electrolyzers by 2031. The company is currently seeking funding opportunities, such as through the i-LAB or EIC Transition schemes, and is actively pursuing partnerships with both private and public stakeholders to accelerate this initiative.