Periodic Reporting for period 1 - ELOXYCHEM (ELectrochemical OXidation of cYclic and biogenic substrates for high efficiency production of organic CHEMicals)
Reporting period: 2024-01-01 to 2025-06-30
ELOXYCHEM aims to develop sustainable, energy-efficient electrochemical processes for producing dicarboxylic acids- a key building block in high-performance materials like polyamides/polyesters, which are widely used in sectors such as high-performance engineering materials, coatings and textiles. ELOXYCHEM covers the entire innovation path from laboratory experiments to design and building a functioning pilot system. To support this, WP1 established a structured data collection approach, including health and safety aspects, enabling robust process assessment and scenario definition. WP2 focused on synthesizing dicarboxylic acids from cycloalkenes using an innovative electrochemical method, employing mild conditions compared to the conventional synthesis. ELOXYCHEM also explores the valorisation of sustainable feedstocks such as tall oil fatty acids (WP3), which are often underutilized. WP7 focuses on designing an efficient and cost-effective downstream process for the main products and side-product valorisation, complemented by a techno-economic assessment to validate commercial-scale feasibility. WP 5 and 9 scale the process to an intermediate level, focusing on reactor integration, optimization, and separation processes. WP10 develops a digital infrastructure combining SCADA, IoT, and digital twin technologies for real-time monitoring and control. This supports the EU’s green and digital transition goals while enhancing the competitiveness of the European chemical industry. WP11 will design and commission a continuous flow pilot plant to demonstrate operational viability at TRL 6. Finally, WP12 ensures the visibility and impact of ELOXYCHEM through a strong exploitation strategy, IPR management, and continuous impact monitoring, supporting the project's long-term sustainability and market readiness.
During the latest project period, WP1 successfully established a structured data collection protocol, including templates, to support comprehensive process assessment and ensure the inclusion of health and safety data. WP2 focused on optimizing the electrochemical oxidation of cycloalkenes. Key parameters such as current density, electrode material, electrolyte composition, and solvent systems were systematically studied. The process evolved from batch to cyclic flow-through electrolysers to enhance scalability. In parallel, methods for oxygenating the electrolyte and strategies for isolating the dicarboxylic acid and recovering solvents were developed. WP2 also simulated power fluctuations to test renewable energy integration, ensuring stable, feasible, and cost-effective operation. Early-stage optimization began for the conversion of tall oil fatty acids, showing positive trends alongside challenges related to substrate reactivity and solubility (WP3). WP5 established an intermediate-scale flow cell, enabling detailed studies of flow dynamics, reaction conditions, and oxygenation strategies. However, ongoing testing of various solvent and electrolyte systems has delayed downstream separation process development. In WP 7, a preliminary downstream process model and Block Flow Diagram were created using the steady state simulator COCO-COFE, incorporating product and solvent recovery, as well as separation of unreacted materials and by-products. These models remain provisional and will be refined based on experimental outcomes from WP2, 5 and 9. Due to dependencies on upstream work, WP9 currently reports on a laboratory scale flow reactor. The results showed no significant electrode degradation, fouling, or swelling, suggesting that electrode degradation is unlikely to pose a major challenge at the pilot scale. In WP10, Deliverable D10.1 was completed, outlining the digital architecture for SCADA, IoT, and AI-enabled data integration. Deployment of ZPR’s iDaQ system and Digital Twin modules has begun, enabling real-time analytics and sensor integration across the pilot line. Nonetheless, a comprehensive dissemination, communication, and exploitation (DC&E) strategy was developed (WP14). This includes stakeholder mapping, tailored messaging, and activation of communication channels such as the project website and social media. Initial outreach included press releases, workshops, and collaboration with related initiatives. A preliminary business case and exploitation strategy were drafted, supported by IPR screenings and market assessments. Tech-Futures Analyses (TFAs) were initiated to monitor freedom to operate and patent landscapes, ensuring the project’s long-term impact and alignment with EU innovation goals.
ELOXYCHEM is expected to deliver a range of impactful results across its work packages. WP1 provides a standardized data collection approach and dataset, essential for consistent process assessment. WP2 targets the development of an electrochemical route to synthesise di-carboxylic acids, a crucial building block in polyamide production, with a wide range of applications for diverse markets – from automotive industry to consumer goods (e. g. sportswear). Unlike conventional methods that rely on toxic reagents and high-temperature processes, ELOXYCHEM’s electrochemical approach operates under milder conditions, reducing hazardous chemical use and potentially cutting energy consumption by up to 60%. The knowledge generated will strengthen Europe’s leadership in electrochemical technologies powered by renewable energy and the valorisation of sustainable feedstocks like tall oil fatty acids, which are typically underused and primarily incinerated for heating purposes. WP3 will further establish a waste-free electrochemical pathway for TOFA valorisation, contributing to the defossilisation of polyamide synthesis and enhancing the sustainability of the European chemical industry. By integrating these renewable resources and utilising advanced digital control systems to optimise the processes, ELOXYCHEM supports the EU’s green and digital transition, positioning Europe as a leader in sustainable chemical manufacturing. The scale-up activities in WP5, 7 and 9 will provide critical insights for optimizing both reaction and separation processes, forming the basis for the demonstrator design in WP11. WP10 will deliver a smart, AI-enabled monitoring and control system for all units. This digital infrastructure will enhance operational efficiency, predict faults, and reduce environmental impact-benefits that can be extended to other industrial sectors. WP11 aims to demonstrate safe, continuous pilot plant operation at production rates of 0.8–3.4 t/year, producing polymer-grade outputs. This will validate the advantages of electrochemical processing, including renewable electricity use, reduced CO2 emissions, and scalable, chemical-free oxidation under moderate conditions. Finally, WP14 will ensure broad dissemination and exploitation of project results to engage stakeholders, raise awareness, and support market uptake. Communication efforts will highlight ELOXYCHEM’s environmental benefits and alignment with EU sustainability goals, laying the groundwork for long-term societal and industrial impact.