Periodic Reporting for period 1 - HYPER (An electrochemically produced oxidiser for modular, onsite generation of HYdrogen PERoxide)
Reporting period: 2023-01-01 to 2024-06-30
The main goal of HYPER is the demonstration at TRL 6 of a scalable, modular electrochemical process for the production of hydrogen peroxide (H2O2). H2O2 is a versatile chemical used in many industries as bleaching agent, chemical reactant or disinfectant. Hence, the integration of the HYPER process into three downstream value-chains, pulp and paper, textiles and chemicals, will be evaluated as a step toward further TRL development. The advances in the HYPER project will transform H2O2 production from a large-volume, energy-intensive process that relies on fossil feedstocks, a cocktail of organic solvents and critical raw material catalysts to a smaller-scale, robust process that requires only water and renewable energy as inputs. The innovation for this transformation is the use of persulphate as an intermediate in the electrochemical process. Persulphate is a stronger, yet more kinetically stable oxidant than H2O2, thus allowing the electrochemical production of persulphate from sulphate salts when renewable electricity is cheap and abundant. The unit for this part of the process is referred to as the electrolyser. H2O2 can then be generated on demand by the reaction of persulphate with water under acidic conditions, recovering sulphate than can undergo another electrochemical cycle. This unit is called the utiliser. Realisation of the HYPER technology is expected to decrease life cycle CO2 emissions for H2O2 production by up to 75% when 100% renewable electricity is used and eliminate at least 19 megatonnes of emissions by 2045. Energy consumption is expected to be reduced by one-third as compared to established production routes.
The project has four technical objectives for realisation of the main goal. Objective 1 is the development of the prototype TRL 4-5 cell, electrode and process. Development of cathodic reactions that will improve the overall Faradaic efficiency of the process are included. This will also ensure that the HYPER process provides added value from both half-reactions. Objective 2 is the development of the TRL 6 cell, electrode and process. The TRL 4-5 pilot will be upscaled and the entire system optimized so that it can operate with fluctuating renewable energy sources and changing current densities. Objective 3 addresses the integration of the HYPER technology into the three downstream value chains. Integration will be demonstrated either by use of H2O2 produced by the TRL 4-5 and TRL 6 pilots within two of the downstream industries, or by a detailed process integration study for the third. Objective 4 is the assessment of the sustainability of the developments. This activity includes economic, life cycle and safety analyses, to ensure that the HYPER process is profitable, actually reduces CO2 emissions and other pollution and is safe to implement.
The project has four technical objectives for realisation of the main goal. Objective 1 is the development of the prototype TRL 4-5 cell, electrode and process. Development of cathodic reactions that will improve the overall Faradaic efficiency of the process are included. This will also ensure that the HYPER process provides added value from both half-reactions. Objective 2 is the development of the TRL 6 cell, electrode and process. The TRL 4-5 pilot will be upscaled and the entire system optimized so that it can operate with fluctuating renewable energy sources and changing current densities. Objective 3 addresses the integration of the HYPER technology into the three downstream value chains. Integration will be demonstrated either by use of H2O2 produced by the TRL 4-5 and TRL 6 pilots within two of the downstream industries, or by a detailed process integration study for the third. Objective 4 is the assessment of the sustainability of the developments. This activity includes economic, life cycle and safety analyses, to ensure that the HYPER process is profitable, actually reduces CO2 emissions and other pollution and is safe to implement.
HYPER has developed stable and less expensive anodes for the oxidation of sulphate to persulphate. These anodes have undergone accelerated aging tests to certify their long-term stability under electrolytic reaction conditions. Stability tests of different electrolyte compositions have been performed to help determine the most optimal cell conditions for the overall reaction. Evaluation of potential cathodic reactions that would provide added value to the downstream partners has resulted in a set of low-risk and high-risk reactions that will permit cell development without compromising potential industrial benefits. The study of persulphate hydrolysis reactions with a range of reactant concentrations and temperatures has resulted in a process for the utilizer that can be integrated with the electrolyser. Static and dynamic process models for each step have been developed to calculate mass and energy balances and realise a piping and instrument diagram. As part of this work, different methods for the analysis of oxidant concentrations have been evaluated, resulting in the development of an on-line measurement technique.
The downstream industrial partners have started their work on the integration of the HYPER technology into their sectors. Experimental procedures for epoxidation with H2O2 are under investigation. Details on the various technologies for bleaching textiles and the use of HYPER-produced H2O2 in these procedures have been mapped. The points of integration between the HYPER technology and the interconnected processes in a kraft pulp mill are under investigation.
The initial techno-economic, life cycle and safety assessments of the HYPER technology have been reported. These analyses have been benchmarked against the current H2O2 production process and other new, alternative processes. A conceptual design and the mass and energy balances for the entire process underpin the conclusions. Operating costs and electricity dominate the economics, and the process cannot be considered competitive with the current production process at this time. However, implementation of potential benefits related to dynamic renewable energy supplies is expected to improve the relative economics. The LCA of the HYPER process shows a higher climate footprint than the current production process, but the footprint is expected to decrease with further process optimisation. The main safety concerns are linked to the use of reactive and unstable substances.
The downstream industrial partners have started their work on the integration of the HYPER technology into their sectors. Experimental procedures for epoxidation with H2O2 are under investigation. Details on the various technologies for bleaching textiles and the use of HYPER-produced H2O2 in these procedures have been mapped. The points of integration between the HYPER technology and the interconnected processes in a kraft pulp mill are under investigation.
The initial techno-economic, life cycle and safety assessments of the HYPER technology have been reported. These analyses have been benchmarked against the current H2O2 production process and other new, alternative processes. A conceptual design and the mass and energy balances for the entire process underpin the conclusions. Operating costs and electricity dominate the economics, and the process cannot be considered competitive with the current production process at this time. However, implementation of potential benefits related to dynamic renewable energy supplies is expected to improve the relative economics. The LCA of the HYPER process shows a higher climate footprint than the current production process, but the footprint is expected to decrease with further process optimisation. The main safety concerns are linked to the use of reactive and unstable substances.
The eventual advancement of the HYPER technology over current production processes will be determined first by the success of the TRL 4-5 pilot unit currently under construction, and thereafter by improvements on that pilot that will be implemented in the TRL 6 unit. It is these process and infrastructure improvements that are expected to provide the anticipated economic, environmental and energy benefits. The development of stable and less expensive anodes for persulphate production is promising for the overall economics. The chemistry of the hydrolysis reaction of persulphate to H2O2 is much better understood and a process scheme for the utilizer is in place. Further understanding of the hydrolysis reaction should lead to an even more efficient and economic process.
Successful demonstration of the TRL 6 pilot unit will pave the way for the rapid commercial development of HYPER units for smaller scale applications, for example within the textiles industry. This assumption is of course predicated on the continued positive development of the techno-economics and life cycle analyses of the HYPER process. Higher prices for HYPER-produced H2O2 as compared to traditionally produced H2O2 will significantly hinder market uptake.
Successful demonstration of the TRL 6 pilot unit will pave the way for the rapid commercial development of HYPER units for smaller scale applications, for example within the textiles industry. This assumption is of course predicated on the continued positive development of the techno-economics and life cycle analyses of the HYPER process. Higher prices for HYPER-produced H2O2 as compared to traditionally produced H2O2 will significantly hinder market uptake.