Periodic Reporting for period 3 - OCEAN (Oxalic acid from CO2 using Eletrochemistry At demonstratioN scale)
Berichtszeitraum: 2020-10-01 bis 2022-07-31
Despite electrochemistry and electrosynthesis being known for decades, application of electrochemical synthesis in industry so far is limited. OCEAN will contribute to develop new advanced electrochemical methodologies to overcome current challenges and create new applications for electrochemistry.
The electrochemical reduction of carbon dioxide to formate is currently one of the most developed, compared to other electrochemical conversion of carbon dioxide. However, despite formic acid being a high valued product, the market is concentrated, small and mature. Therefore, OCEAN aims at integrating the electrochemical reduction of carbon dioxide by producing oxalic acid and high-value products made thereof.
We demonstrate in the project, by techno economic and LCA analyses, that it is necessary to address C2 products from CO2, rather than formate/formic acid to create strong business cases and thus make a significant step forward in bringing electrochemical technologies to the market, fully integrated in a chemical process.
This project will reduce the environmental impact of society (reducing its CO2 footprint) treating carbon dioxide as a resource instead of a waste product will have major ramifications.
If captured carbon dioxide is used to produce glycolic acid and oxalic acid and subsequently consumer products thereof, petroleum-based counterparts can be replaced in the market. The replacement of the petroleum-based counterpart with carbon dioxide-based intermediates can reduce the imports of crude oil and in general reduce the dependency on raw material imports.
These technologies offer new perspectives and close the carbon-cycle in energy-intensive industries.
Operating the largest CO2 reduction cell at scale (0.2m2 and 1 meter in height) for 1040 hours in the RWE facility, OCEAN has demonstrated the viability of CO2 reduction at scale. This allowed for the validation of the electrochemical technology at an industrial scale. Along with validation of CO2 to formate, the anodic reaction was also scaled (paired electrolysis) with positive conclusions regarding the overall efficiencies for the cell, 150% (80% cathodic + 70% anodic), and co-production ~400 hours at the scale described above, in thsi respect, we could have an 80% efficiency at the cathode (CO2 to formate) and 70% at the anode (glycerol to formate).
The electrochemical reduction of carbon dioxide to formate is currently one of the most developed, compared to other electrochemical conversion of carbon dioxide. However, despite formic acid being a high valued product, the market is concentrated, small and mature. Therefore, OCEAN aims at integrating the electrochemical reduction of carbon dioxide by producing oxalic acid and high-value products made thereof.
We demonstrate in the project, by techno economic and LCA analyses, that it is necessary to address C2 products from CO2, rather than formate/formic acid to create strong business cases and thus make a significant step forward in bringing electrochemical technologies to the market, fully integrated in a chemical process.
This project will reduce the environmental impact of society (reducing its CO2 footprint) treating carbon dioxide as a resource instead of a waste product will have major ramifications.
If captured carbon dioxide is used to produce glycolic acid and oxalic acid and subsequently consumer products thereof, petroleum-based counterparts can be replaced in the market. The replacement of the petroleum-based counterpart with carbon dioxide-based intermediates can reduce the imports of crude oil and in general reduce the dependency on raw material imports.
These technologies offer new perspectives and close the carbon-cycle in energy-intensive industries.
Operating the largest CO2 reduction cell at scale (0.2m2 and 1 meter in height) for 1040 hours in the RWE facility, OCEAN has demonstrated the viability of CO2 reduction at scale. This allowed for the validation of the electrochemical technology at an industrial scale. Along with validation of CO2 to formate, the anodic reaction was also scaled (paired electrolysis) with positive conclusions regarding the overall efficiencies for the cell, 150% (80% cathodic + 70% anodic), and co-production ~400 hours at the scale described above, in thsi respect, we could have an 80% efficiency at the cathode (CO2 to formate) and 70% at the anode (glycerol to formate).
OCEAN is a four-year and 10 months project, organized in three consecutive phases.
The first phase (first 2 years) of the project was dedicated to the development of new electrochemical technologies (electrically driven reactions to produce the require chemicals) as well as upscaling and optimization of the electrochemical reduction of carbon dioxide in an industrial context.
The second phase (third year) was devoted to the optimization, engineering, and manufacturing of the large-scale units.
The further period was dedicated to testing and demonstration/validation of the industrial feasible units, these tests were conducted in environmentally relevant conditions (TRL 6). That is, on-site in a power plant utilizing captured CO2 form the facility.
During the first period (first 18th months) seven of the WPs were active, except WP6 (LCA). A few tasks ended in the 1st period, but most of the tasks and all WPs were active in the 2nd reporting period. The activities were in good agreement with those planned, but with some delays related to general pandemic situation that limited most of the activities and caused delays. Except for some shift due to these aspects, no key issues were identified in the deliverables and milestones. These were achieved according to expectations with minor changes subjected to two amendments.
The duration of the actions of the OCEAN project were extended to 58 months.
The outcome of OCEAN provided a value proposition of glyoxylic acid with the many important insights. With these insights a business case can be expanded to other markets as time progresses, utilizing the same techniques applied to the OCEAN business case and market analysis. From electrode development, the focus on the sales of standard products implementing the versions made in OCEAN will be a standard. Also, the continuation of manufacturing of custom-tailored gas diffusion electrodes for various CO2 reduction applications is on-going. With the insights from OCEAN, identification of a better produced and cheaper gas diffusion electrodes to deliver to the market will be a future objective. The design of the stack and the design of the processing unit will be used in future R&D projects to further upscale electrochemical technology to market level and commercialisation. The stack design can also be used to investigate other processes for the CO2 electroreduction beyond the OCEAN project (i.e. CO2 reduction to C+ products).
The further exploitation of the CO2 conversion scaled in OCEAN is a key step in the market acceptance of electrochemical conversion of CO2 to chemicals.
As business cases change over time and positive reaction from experts in the field increase, another course, away from Glyoxylic acid as a main product, has been linked. Formic acid and CO2 to PLGA have been identified as the next value proposition. More customer traction has been made in the market of formic acid and plastics from polymers in business development as of today.
The new course of Avantium has been designed in such a way to build partnerships on the full OCEAN process of CO2 to plastics, i.e. PLGA as a final product. Glyoxylic acid is still a product that is presented to the public as a business proposition when Avantium is advertising in the market. There is some interest from the market, but it is slow moving as most of the glyoxylic acid is in cosmetics and food additives and health and safety of newly introduced products in this market is a key factor in acceptance but has a long lead time.
The first phase (first 2 years) of the project was dedicated to the development of new electrochemical technologies (electrically driven reactions to produce the require chemicals) as well as upscaling and optimization of the electrochemical reduction of carbon dioxide in an industrial context.
The second phase (third year) was devoted to the optimization, engineering, and manufacturing of the large-scale units.
The further period was dedicated to testing and demonstration/validation of the industrial feasible units, these tests were conducted in environmentally relevant conditions (TRL 6). That is, on-site in a power plant utilizing captured CO2 form the facility.
During the first period (first 18th months) seven of the WPs were active, except WP6 (LCA). A few tasks ended in the 1st period, but most of the tasks and all WPs were active in the 2nd reporting period. The activities were in good agreement with those planned, but with some delays related to general pandemic situation that limited most of the activities and caused delays. Except for some shift due to these aspects, no key issues were identified in the deliverables and milestones. These were achieved according to expectations with minor changes subjected to two amendments.
The duration of the actions of the OCEAN project were extended to 58 months.
The outcome of OCEAN provided a value proposition of glyoxylic acid with the many important insights. With these insights a business case can be expanded to other markets as time progresses, utilizing the same techniques applied to the OCEAN business case and market analysis. From electrode development, the focus on the sales of standard products implementing the versions made in OCEAN will be a standard. Also, the continuation of manufacturing of custom-tailored gas diffusion electrodes for various CO2 reduction applications is on-going. With the insights from OCEAN, identification of a better produced and cheaper gas diffusion electrodes to deliver to the market will be a future objective. The design of the stack and the design of the processing unit will be used in future R&D projects to further upscale electrochemical technology to market level and commercialisation. The stack design can also be used to investigate other processes for the CO2 electroreduction beyond the OCEAN project (i.e. CO2 reduction to C+ products).
The further exploitation of the CO2 conversion scaled in OCEAN is a key step in the market acceptance of electrochemical conversion of CO2 to chemicals.
As business cases change over time and positive reaction from experts in the field increase, another course, away from Glyoxylic acid as a main product, has been linked. Formic acid and CO2 to PLGA have been identified as the next value proposition. More customer traction has been made in the market of formic acid and plastics from polymers in business development as of today.
The new course of Avantium has been designed in such a way to build partnerships on the full OCEAN process of CO2 to plastics, i.e. PLGA as a final product. Glyoxylic acid is still a product that is presented to the public as a business proposition when Avantium is advertising in the market. There is some interest from the market, but it is slow moving as most of the glyoxylic acid is in cosmetics and food additives and health and safety of newly introduced products in this market is a key factor in acceptance but has a long lead time.
OCEAN demonstrates the possibility of a new value chain to produce C2 chemicals from CO2 and renewable energy via electrocatalysis. Non-renewable feedstock uses and greenhouse gas emissions can be substantially reduced compared to petro-based plastics by using captive carbon dioxide. A significant saving of > 30% in energy-intensity and greenhouse gas emissions is expected, with a great impulse on the development of an electrocatalytic-based industry in Europe and in general in strengthening the global position of European process industry.
OCEAN will enable new routes to existing (bulk) chemicals with a significant market value. Initial Techno-economic assessments have shown potential production cost advantages for the target products. Updated business cases will be developed in the OCEAN project.
Between relevant impact elements of the project the following can be indicated:
a. Demonstrate novel electrocatalytic processes up to TRL 6
b. Develop improved electrocatalytic technologies
c. Develop improved electrocatalysts
d. Demonstrate feasibility of the novel value chain of CO2 to C2 chemicals
e. Develop improved hydrogenation catalysts for the selective reduction of oxalic acid as alternative to electrocatalytic one
Turning carbon dioxide into an opportunity rather than liability has the potential to bring huge benefits to chemical producers, companies producing (waste) CO2, brand owners, and the environment.
OCEAN will enable new routes to existing (bulk) chemicals with a significant market value. Initial Techno-economic assessments have shown potential production cost advantages for the target products. Updated business cases will be developed in the OCEAN project.
Between relevant impact elements of the project the following can be indicated:
a. Demonstrate novel electrocatalytic processes up to TRL 6
b. Develop improved electrocatalytic technologies
c. Develop improved electrocatalysts
d. Demonstrate feasibility of the novel value chain of CO2 to C2 chemicals
e. Develop improved hydrogenation catalysts for the selective reduction of oxalic acid as alternative to electrocatalytic one
Turning carbon dioxide into an opportunity rather than liability has the potential to bring huge benefits to chemical producers, companies producing (waste) CO2, brand owners, and the environment.