Periodic Reporting for period 2 - HYPER (An electrochemically produced oxidiser for modular, onsite generation of HYdrogen PERoxide)
Période du rapport: 2024-07-01 au 2025-12-31
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. 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 performed extensive studies to determine the most optimum process for the hydrolysis of persulfate to H2O2. This has resulted in a process design and process control interface for the utiliser. The utiliser has been constructed and thoroughly tested. After commissioning of the TRL 6 electrolyser, this unit was integrated with the utiliser to provide the project’s TRL 4-5 mini-plant that was successfully deployed at textile partner InoTex. The mini-plant is now back at primary development partner JSI for upgrading to the TRL 6 pilot. A HAZOP study of the utiliser was conducted to ensure its safe operation.
Throughout the utiliser process development, samples of H2O2 from electrochemically generated persulfate (e-H2O2) were sent to InoTex where they were tested in four different bleaching processes for cottons and yarns. HYPER’s e-H2O2 performed in these bleaching studies as well as commercial H2O2. This was confirmed with the e-H2O2 produced by the mini-plant during its deployment at InoTex.
Parallel with the mini-plant development, studies on electrode development and integration of the HYPER process with downstream industries continued. A cheaper but similarly robust and long-lived anode has been developed, but it will not be possible to integrate this electrode into the TRL 6 pilot, since it requires a redesign of the electrolyser. By-products from pulp mill processes can be used as electrolyte in the oxidation process, and a catholytic reaction for the recovery of indigo in textiles processing has been developed. The benchmark experimental procedures for epoxidation and emulsification with H2O2 and use with the TRL 6 pilot are nearing completion.
Work on the techno-economic evaluation, life cycle assessment and safety considerations of the HYPER technology have continued. Despite improvements in the overall process underpinning the techno-economics, but the anticipated price is still higher about 2.5 times higher than the project KPI for this metric. The life cycle assessment also shows improvement in the overall greenhouse gas emission reductions. With the complete implementation of renewable energy, the intended reduction in CO2 emissions as compared to the state-of-the-art technology can be surpassed. In addition to the HAZOP studies, experimental studies of reactive hazards within the HYPER process are underway to improve the overall safety profile.
Throughout the utiliser process development, samples of H2O2 from electrochemically generated persulfate (e-H2O2) were sent to InoTex where they were tested in four different bleaching processes for cottons and yarns. HYPER’s e-H2O2 performed in these bleaching studies as well as commercial H2O2. This was confirmed with the e-H2O2 produced by the mini-plant during its deployment at InoTex.
Parallel with the mini-plant development, studies on electrode development and integration of the HYPER process with downstream industries continued. A cheaper but similarly robust and long-lived anode has been developed, but it will not be possible to integrate this electrode into the TRL 6 pilot, since it requires a redesign of the electrolyser. By-products from pulp mill processes can be used as electrolyte in the oxidation process, and a catholytic reaction for the recovery of indigo in textiles processing has been developed. The benchmark experimental procedures for epoxidation and emulsification with H2O2 and use with the TRL 6 pilot are nearing completion.
Work on the techno-economic evaluation, life cycle assessment and safety considerations of the HYPER technology have continued. Despite improvements in the overall process underpinning the techno-economics, but the anticipated price is still higher about 2.5 times higher than the project KPI for this metric. The life cycle assessment also shows improvement in the overall greenhouse gas emission reductions. With the complete implementation of renewable energy, the intended reduction in CO2 emissions as compared to the state-of-the-art technology can be surpassed. In addition to the HAZOP studies, experimental studies of reactive hazards within the HYPER process are underway to improve the overall safety profile.
The TRL 4-5 mini-plant has been constructed and deployed, and upgrading to the TRL 6 unit is underway. The mini-plant included the TRL 6 electrolyser, and the persulphate production rate exceeded the Key Performance Indicator for that metric. Upgrades to the mini-plant will therefore focus on energy and efficiency improvements to the utiliser and process modifications that will ensure full automation, semi-continuous operation and closed-loop recycling of the electrolyte between the anolyte, catholyte and utiliser.
Revised techno-economic and life cycle analyses show that the HYPER process can exceed its energetic and GHG emissions reduction targets, although the economic target is still lagging. The emission reduction target is dependent on the eventual availability of fully renewable electricity that can run the process. The fully automated and integrated HYPER process (electrolyser + utiliser) that will be implemented in the TRL 6 pilot is needed to substantiate these analyses.
The success of the mini-plant and the anticipated successful demonstration of the TRL 6 pilot unit provides the necessary runway for a follow-up project that will take the HYPER process to higher TRL and pave the way for the rapid commercial development of HYPER units for modular applications..
Revised techno-economic and life cycle analyses show that the HYPER process can exceed its energetic and GHG emissions reduction targets, although the economic target is still lagging. The emission reduction target is dependent on the eventual availability of fully renewable electricity that can run the process. The fully automated and integrated HYPER process (electrolyser + utiliser) that will be implemented in the TRL 6 pilot is needed to substantiate these analyses.
The success of the mini-plant and the anticipated successful demonstration of the TRL 6 pilot unit provides the necessary runway for a follow-up project that will take the HYPER process to higher TRL and pave the way for the rapid commercial development of HYPER units for modular applications..