Periodic Reporting for period 2 - UP-TO-ME (Unmanned-Power-to-Methanol-production)
Periodo di rendicontazione: 2024-05-01 al 2025-10-31
The UP-TO-ME project aimed at creating Unmanned- Power-to-Methanol-production by combining the capture of CO2 with the synthesis of methanol, in a fully autonomous unmanned plant. The technology enables the use of CO2 from point sources utilising locally available renewable energy making small scale production of methanol economically competitive for the first time.
The fully automated, self-learning and self-optimising control system allows the production of methanol under fluctuating conditions. This can be achieved by combining dynamic plant models and artificial intelligence to provide self-optimising control for off-grid operations, which is very challenging and has never been done before. The ability of a remote plant to adapt itself to varying boundary conditions such as the availability of renewable energies, or the availability of CO2 from a fluctuating source will open a variety of possibilities for distributed production.
UP-TO-ME targets a ground-breaking change in decentralised Power-to-Methanol production for hard-to-electrify applications, such as marine vessels and heavy goods vehicles (HGV).
The specific objectives of the project were:
• To convert decentralised CO2 point-sources to production sites for renewable fuels.
• Develop reliable and cost-effective technology for utilising the point sources of CO2.
• To speed up the transition to a net-zero greenhouse gas emissions in the EU.
• To develop an intensified and fully automated process for decentralised production of renewable methanol.
• To communicate, disseminate and transfer project results for their wider implementation and replication in different sectors where a renewable biofuel will be useful.
• To produce a total of at least 100 litres of concentrated methanol in the experimental plant.
• To experimentally assess the suitability of the produced fuel on a marine type of engine.
The work towards the goals progressed well as planned and all technology-related milestones were reached on time:
The Proof-of-Concept (PoC) of UP-TO-ME-technology was well achieved by the end of the project. The hybrid technology plant demonstrated a CO2 yield of 91% and capture efficiency producing raw methanol at 46 mole% with a daily rate of 50 liters. The distilled methanol reached a purity of 99%.
The fully automated, self-learning and self-optimising control system allows the production of methanol under fluctuating conditions. This can be achieved by combining dynamic plant models and artificial intelligence to provide self-optimising control for off-grid operations, which is very challenging and has never been done before. The ability of a remote plant to adapt itself to varying boundary conditions such as the availability of renewable energies, or the availability of CO2 from a fluctuating source will open a variety of possibilities for distributed production.
UP-TO-ME targets a ground-breaking change in decentralised Power-to-Methanol production for hard-to-electrify applications, such as marine vessels and heavy goods vehicles (HGV).
The specific objectives of the project were:
• To convert decentralised CO2 point-sources to production sites for renewable fuels.
• Develop reliable and cost-effective technology for utilising the point sources of CO2.
• To speed up the transition to a net-zero greenhouse gas emissions in the EU.
• To develop an intensified and fully automated process for decentralised production of renewable methanol.
• To communicate, disseminate and transfer project results for their wider implementation and replication in different sectors where a renewable biofuel will be useful.
• To produce a total of at least 100 litres of concentrated methanol in the experimental plant.
• To experimentally assess the suitability of the produced fuel on a marine type of engine.
The work towards the goals progressed well as planned and all technology-related milestones were reached on time:
The Proof-of-Concept (PoC) of UP-TO-ME-technology was well achieved by the end of the project. The hybrid technology plant demonstrated a CO2 yield of 91% and capture efficiency producing raw methanol at 46 mole% with a daily rate of 50 liters. The distilled methanol reached a purity of 99%.
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.
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.
A process for the unmanned production of methanol from CO2 was built and operated successfully. The plant utilized an actively cooled reactor for methanol production, inserts and structured packings that were designed with the aid of advanced CFD-modelling and manufactured by 3D-printing in the project. Hundreds of liters of methanol were successfully produced in the experimental plant utilizing the UP-TO-ME-technology and the suitability of the produced methanol as marine fuel was demonstrated by engine tests and chemical analysis.
A concrete outcome of the project was the founding of a start-up company ICODOS GmbH in October 2022. ICODOS is a spin-off company of KIT. Encouraged by the highly promising results already at these early stages of the UP-TO-ME-project ICODOS will continue the development and commercialization of the UP-TO-ME technology. ICODOS was included in the Consortium as an Associated Partner in July 2023. During the reporting period ICODOS has grown fast employing already 25 young European professionals.
A concrete outcome of the project was the founding of a start-up company ICODOS GmbH in October 2022. ICODOS is a spin-off company of KIT. Encouraged by the highly promising results already at these early stages of the UP-TO-ME-project ICODOS will continue the development and commercialization of the UP-TO-ME technology. ICODOS was included in the Consortium as an Associated Partner in July 2023. During the reporting period ICODOS has grown fast employing already 25 young European professionals.