Technology Development and Scaling:
In 2024, a physically operating plant at TRL 6 was realised. The next milestone in 2025 saw operations at a WWTP, advancing to TRL 7. A key achievement includes simulating a plant scaled up by a factor of 50, using regressed binary interaction parameters and rate-based simulations. The hybrid technology plant demonstrated a CO2 yield of 91% and capture efficiency of 95%, producing raw methanol at 46 mole% with a daily rate of 50 liters. The distilled methanol reached a purity of 99%. Additionally, the technology showcased a CO2 capture efficiency of 83% and a methanol production rate of 34 liters per day with 50 mole% purity.
Performance Assessment and Fault Detection
Lab-scale testing of 3D printed reactors has been successful leading to further optimized reactor packing configurations. Performance assessment was supported by advanced fault detection (85% rate), fault classification (82% accuracy), and fault localization (97% accuracy). These metrics underscore the reliability and robustness of the technology in operational environments.
Implementation and investigation of various column packing configurations at plant scale allowed for direct comparison between 3D printed reactors and conventional industrial packing, facilitating the identification of optimal setups for scalability and industrial relevance.
Techno-Economic and Environmental Assessments
Comprehensive TEA and LCA was performed, with pilot plant costs scaled up from units not optimized for cost. Notably, methanol production costs can be significantly reduced by improving plant efficiency and facilitating mass production. The environmental outcomes are impressive, with a well-to-tank global warming potential (GWP) that is net negative. Case studies in the Greek Archipelago, specifically in Heraklion, reveal a GWP reduction of −91.7% compared to marine gas oil (MGO), −71.5% versus ammonia (NH₃), and −33.8% versus hydrogen (H2).
Engine Testing and Methanol Quality
Methanol produced through this technology has undergone thorough quality analysis, establishing technical specifications and regulatory frameworks for marine sector use. The fuel properties are linked with ISO and IMPCA standards, and engine testing provides valuable well-to-wake data that highlight emission reduction potential, particularly with EATS scrubber technology. Higher water content in methanol—beyond ISO 6583:2024 limits—may reduce production costs and decrease engine-out NOx emissions, without immediate harm to engines or aftertreatment systems up to 2 wt% water content. However, elevated water content raises corrosion concerns, necessitating further study and the development of additives to prevent corrosion and improve lubricity. The technology addresses the growing demand for renewable methanol in the marine sector and offers future opportunities to use various CO2-rich gases as feedstocks and employ methanol in zero-emission vehicles. The strong TEA and LCA framework supports stakeholder decision-making for distributed Power-to-X plants and demonstrates a sustainable way of producing methanol for marine fuel.
Conclusion
The UPTOME project stands out as a pioneering effort in hybrid methanol production, integrating advanced CO2 capture and synthesis technologies within WWTPs and aligning with circular economy principles. Continued collaboration, technical innovation, and regulatory harmonization will be essential for overcoming remaining challenges and realizing the full potential of renewable methanol in the energy transition.
