Formate for Renewable Energy Storage

Project Information

FRESH

Grant agreement ID: 101069605

DOI

10.3030/101069605

Project closed

EC signature date 8 June 2022

Start date 1 July 2022

End date 31 December 2025

Funded under

• Climate, Energy and Mobility

Total cost

€ 2 987 730,00

EU contribution

€ 2 987 729,75

Coordinated by

CONSIGLIO NAZIONALE DELLE RICERCHE
Italy

Periodic Reporting for period 2 - FRESH (Formate for Renewable Energy Storage)

Reporting period: 2024-01-01 to 2025-12-31

Summary of the context and overall objectives of the project

FRESH aims to contribute to reducing the European Union’s dependence on fossil fuels for power generation, providing a cushion for the intermittent character of renewable electricity generation leading to stable, more predictable prices for renewable electricity, which is crucial for the future development of large-scale renewable power generation, and therefore, the energy transition. The project has achieved this through the development, construction and validation, of an integrated, cost competitive process for conversion of CO2 to potassium formate using an electrocatalytic process powered by renewable electricity. The highly stable potassium formate generated by the reactor will be stored safely for long periods (from short term or seasonal) in tanks. The subsequent conversion of the stored potassium formate to electricity on demand will use a direct fuel cell system.

The project includes development of the individual components (CO2 to formate and formate to electricity), CO2 sourcing and purification and ultimately the construction and validation of an integrated protoype. This will be achieved by the implementation of a series of interconnected work packages. FRESH is structured around five technical work packages and two ‘enabling/value adding’ work packages, supporting dissemination, exploitation and management activities. Development of the CO2 to Potassium Formate reactor in WP2. In WP3, power generation from Potassium Formate will be investigated using direct fuel cell systems. Integration of variable simulated industrial CO2 sources and purification capabilities in WP4.

The tasks regarding these three technologies will be carried out in parallel. Special attention will be given to the tuning of the Potassium Formate stream from the CO2 electrolyzer. Finally, the overall prototype will be designed with the knowledge and output acquired from WP2, WP3 and WP4. This WP involves construction and operation of the prototype plant. WP5 is also dedicated to the validation of the complete system, as well as performing system trials. WP6 involves a variety of analyses to ensure sustainable choices and realistic input parameters in other WPs. A Life Cycle Assessment and Techno-economic analysis will be carried out along with a financial and market study.

The consortium consists of 8 partners of which 3 research institutes (CNR, CERTH and FZJ), 4 industrial partners (COVAL Energy, ENGIE laboelec, HYSYTECH, EEMPOWER) and 1 university (DTU) from 6 EU member states.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Over the period of the project scientific activities have revolved around the three technical work packages; WP2 Electrochemical process/reactor development – CO2 conversion system, WP3 Power generation system – PF re-electrification module and WP4 Renewable CO2 Capture and Source.

In WP2, research has been undertaken to optimize the reactor for the transformation of CO2 to potassium formate. In parallel to this technical study, a Front-End Engineering Design was developed for the CO2 electrolyzer including an optional post reactor purification process. The research work carried out in WP2 has improved the reactor performance by using a zero-gap architecture, testing different membranes, improving the flow distribution and improving the anode and cathode materials.

Work in WP3, the successful manufacture of up-scaled electrodes for incorporation and testing in a fuel cell stack was completed. The fuel cell STACK with up to 35 cells has been designed and constructed and tested.

In WP4, work has involved investigations into suitable sources of CO2 for the FRESH technology. This work involved mapping of biogenic CO2 sources in the EU and comparison with other CO2 point sources. The CO2 to be fed into the CO2 to formate reactor may contain various impurities that highly depend upon the nature of the CO2 source. All of the impurities identified were analysed for their potential impact on the catalysts or with the electrolyte of the electrolysis cell. The results of this study have identified the best matches of CO2 source for the FRESH technology. Carbon capture trials were undertaken on a mini-pilot, optimizing the process for CO2 content purity and for CO2 sources and investigation of impurities. Tests were also undertaken on a semi pilot MGA Membrane Gas Adsorption unit.

The above activities fed into WP5 where the prototype for the FRESH technology was designed and constructed. The prototype was designed as three units that operate independently; (i) The CO2 to formate electrolyser, the fuel cell for transforming formate into electricity and (iii) an electrodialysis unit for transforming excess formate into formic acid. Finally, the prototype was tested and evaluated at TRL4 at the Hysytech labs.

A complete Life cycle and techno-economic assessment undertaken and an analysis of a market model was developed to study the economic viability of the FRESH technology in the framework of renewable energy markets.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The FRESH project has brought together two electrochemical technologies applying them as a renewable energy storage process. The project has demonstrated how a e-Fuel (potassium formate) produced from the electrolysis of CO2 can be stored and then transformed into electricity on demand in a fuel cell. This has taken the TRL from 2 to 4 through the construction of a prototype demonstrator together with a virtual plant model of the processes. A parallel study on the carbon capture technologies was undertaken and the overall feasibility (environmental, economical and market) of the technology was evaluated.

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