Periodic Reporting for period 1 - NextFuel (Industrialising eSMR to Supply the Next Shipping Fuels)
Période du rapport: 2023-12-01 au 2025-02-28
The key new technology in this project is the new eSMR reactor, that we for the first time (on a global basis) use at industrial scale. The basis of our innovation is to pilot a novel approach to producing methanol, never before piloted beyond our project partners lab scale prototype, where we use an electrically heated stream methane reformer (eSMR) instead of present firing of natural gas in the fired reformer (used in conventional methanol synthesis). The scientific background of the innovation is a successful lab prototype and many publications describing parts of the work in journals including Science. The eSMR technology can allow very compact reactor designs, up to 100 times smaller than current SMR plants, which combined with higher energy efficiency and no directly associated CO2 emission, makes the eSMR reactor extremely commercially attractive for synthesis gas production. The cost-efficient and scalable solution can be built as a realistic alternative to fossil methanol production. In the project Topsoe delivers the process plant to Molgas (LNG company) that in turn want to market sustainable ship fuels. We have a first customer in the project, that operates two feeder container vessels running on methanol. With the assistance of leading research groups covering both optimizing resource streams (NTNU) and ecosystem simulations (CERTH), we develop a comprehensive plan to pathways of bringing eSMR-based plant designs to efficient and widespread use in Europa.
The project will enable production of renewable methanol from using our eSMR approach, to enable a cost closer to the fossil alternative, and to study how this approach can be successfully scaled. The project’s impact is significant towards supporting EU’s ambitious targets to cut emissions in the maritime sector.
One of our main objectives is to provide an ecosystem simulation platform that predicts energy efficiency (using the demonstrator as the case) with +80% accuracy, by combining process simulations (by TOPSOE), resource simulations (by NTNU) and value chain simulations (by CERTH), utilising the industrial know-how while we bring state-of-the-art simulation approaches to methanol production (and its ecosystem). Another objective is to improve carbon efficiency from present 40% of fossil derived methanol defining a pathway to +90% carbon efficiency.
We develop the project in three phases. In the first we develop the generic models. This covers frameworks to agree to model information relevant to biomethanol plant sizes and requirements, which in turn is built on information in areas such as environmental impact, cost impact, feedstock availability, logistics solutions and more. This is then used to build simulation models of plants and ecosystems, focusing on key unsolved areas such as energy integration with the biogas plant as well as hydrogen integration. Both of these feed into the plant design, where the size is also set and next the detailed design. We target copy-paste plant designs, as design is a substantial part of cost. From the plant design we get the key process-module of the eSMR technology, which is then shipped to the next step. Here we demonstrate an operational plant, and both validate our approaches (including the world’s first industrial pilot of eSMR and the biogas-eSMR integration). All the project experience is next used in developing the tools to configure plants and value chains, that are then tested on conceptual designs (covering business models, environmental impact and more) for different plant sizes (including considerable scale-ups from the demonstrator plant).
The project will enable production of renewable methanol from using our eSMR approach, to enable a cost closer to the fossil alternative, and to study how this approach can be successfully scaled. The project’s impact is significant towards supporting EU’s ambitious targets to cut emissions in the maritime sector.
One of our main objectives is to provide an ecosystem simulation platform that predicts energy efficiency (using the demonstrator as the case) with +80% accuracy, by combining process simulations (by TOPSOE), resource simulations (by NTNU) and value chain simulations (by CERTH), utilising the industrial know-how while we bring state-of-the-art simulation approaches to methanol production (and its ecosystem). Another objective is to improve carbon efficiency from present 40% of fossil derived methanol defining a pathway to +90% carbon efficiency.
We develop the project in three phases. In the first we develop the generic models. This covers frameworks to agree to model information relevant to biomethanol plant sizes and requirements, which in turn is built on information in areas such as environmental impact, cost impact, feedstock availability, logistics solutions and more. This is then used to build simulation models of plants and ecosystems, focusing on key unsolved areas such as energy integration with the biogas plant as well as hydrogen integration. Both of these feed into the plant design, where the size is also set and next the detailed design. We target copy-paste plant designs, as design is a substantial part of cost. From the plant design we get the key process-module of the eSMR technology, which is then shipped to the next step. Here we demonstrate an operational plant, and both validate our approaches (including the world’s first industrial pilot of eSMR and the biogas-eSMR integration). All the project experience is next used in developing the tools to configure plants and value chains, that are then tested on conceptual designs (covering business models, environmental impact and more) for different plant sizes (including considerable scale-ups from the demonstrator plant).
WP3 - Simulation & Optimization
Established a modelling framework in Aspen Plus following a literature review and definition of a preliminary base case. Process simulations were carried out for multiple feedstock scenarios (biomethane, biogas, CO2), including flexible stoichiometry adjustment. Sensitivity analyses and scenario studies were conducted to optimise operating conditions and process configurations. Renewable power demand, hydrogen and syngas balances, utility requirements, energy efficiency and carbon utilisation were quantified to support downstream engineering work.
WP4 - Plant Design & Optimization
The 150 MTPD biomethanol plant was developed from feasibility study through Design Basis, BEDP and FEED. The Design Basis defined technical, operational, safety and regulatory boundary conditions. Engineering activities included development of PFDs and P&IDs, equipment sizing and specifications, control and safety system definition (including preliminary HAZOP inputs), electrical design, budget estimation, and preparation of a 30% 3D model. Parallel site preparation activities addressed permitting, grid connection, feedstock and offtake agreements, financing dialogue, and integration with the selected EPC contractor.
WP5 - Data & Demonstration
The FEED documentation was consolidated into an overall EPC contracting and execution model together with the selected EPC contractor. Project structuring, risk allocation principles and procurement planning frameworks were developed to prepare the transition from engineering to construction.
Main achievements
• Completion of advanced process simulations enabling a flexible and robust plant concept capable of operating on a wide range of feedstocks.
• Quantification of energy balances, renewable power demand and carbon utilisation, providing validated input for plant design and impact assessment.
• Delivery of the full Design Basis, BEDP and FEED for the 150 MTPD plant, including several hundred engineering documents and a 30% 3D model.
• Technical validation of the eREACT-based biomethanol process as design-ready and suitable for industrial implementation.
• Establishment of a firm bid basis for core plant modules and development of an EPC contracting and procurement framework.
• Significant reduction of technical and implementation risks, positioning the project for Final Investment Decision (FID) and transition to construction in the next reporting period.
Established a modelling framework in Aspen Plus following a literature review and definition of a preliminary base case. Process simulations were carried out for multiple feedstock scenarios (biomethane, biogas, CO2), including flexible stoichiometry adjustment. Sensitivity analyses and scenario studies were conducted to optimise operating conditions and process configurations. Renewable power demand, hydrogen and syngas balances, utility requirements, energy efficiency and carbon utilisation were quantified to support downstream engineering work.
WP4 - Plant Design & Optimization
The 150 MTPD biomethanol plant was developed from feasibility study through Design Basis, BEDP and FEED. The Design Basis defined technical, operational, safety and regulatory boundary conditions. Engineering activities included development of PFDs and P&IDs, equipment sizing and specifications, control and safety system definition (including preliminary HAZOP inputs), electrical design, budget estimation, and preparation of a 30% 3D model. Parallel site preparation activities addressed permitting, grid connection, feedstock and offtake agreements, financing dialogue, and integration with the selected EPC contractor.
WP5 - Data & Demonstration
The FEED documentation was consolidated into an overall EPC contracting and execution model together with the selected EPC contractor. Project structuring, risk allocation principles and procurement planning frameworks were developed to prepare the transition from engineering to construction.
Main achievements
• Completion of advanced process simulations enabling a flexible and robust plant concept capable of operating on a wide range of feedstocks.
• Quantification of energy balances, renewable power demand and carbon utilisation, providing validated input for plant design and impact assessment.
• Delivery of the full Design Basis, BEDP and FEED for the 150 MTPD plant, including several hundred engineering documents and a 30% 3D model.
• Technical validation of the eREACT-based biomethanol process as design-ready and suitable for industrial implementation.
• Establishment of a firm bid basis for core plant modules and development of an EPC contracting and procurement framework.
• Significant reduction of technical and implementation risks, positioning the project for Final Investment Decision (FID) and transition to construction in the next reporting period.
We advanced beyond the current state of the art by maturing an electrified biomethanol production concept to full FEED level for a 150 MTPD plant, significantly reducing technical risk and validating the robustness and flexibility of the selected eREACT process for multiple feedstocks. The structured engineering workflow (from feasibility to FEED), including modelling, safety assessments and multidisciplinary design reviews, has resulted in an investment‑ready plant design and a firm bid basis, thereby moving the concept from theoretical feasibility toward industrial deployment. Early dissemination activities have strengthened the scientific basis for methanol as a sustainable marine fuel and increased visibility within the research community. To ensure further uptake and impact, key next steps include securing Final Investment Decision (FID), progressing to procurement and construction, continued demonstration of operational performance, access to finance, and alignment with supportive regulatory and maritime fuel standardisation frameworks.