Periodic Reporting for period 3 - MOF4AIR (Metal Organic Frameworks for carbon dioxide Adsorption processes in power production and energy Intensive industRies)
Reporting period: 2022-07-01 to 2025-01-31
Power supply and carbon-intensive industries account for a large share of anthropogenic CO2 emissions to the atmosphere and play an important role in the greenhouse effect and global warming. Shifting towards a low-carbon economy requires, in addition to reductions at the source and increased use of renewable energy, the development, testing, and deployment of cost-effective carbon capture solutions. Current high maturity solutions suffer from high energy penalties and environmental impacts. Adsorption processes are promising alternatives for capturing CO2 from power plants and other energy-intensive industries such as cement, steel, and petrochemical. In this context, Metal Organic Frameworks (MOFs) are a widely studied class of porous adsorbents that offer tremendous potential, owing to their high CO2 adsorption capacity and high affinity for CO2. However, the performances of MOF-based carbon capture technologies have not yet been fully assessed on an industrial scale. The MOF4AIR project gathers 14 partners from 8 countries to develop and demonstrate the performances of MOF-based CO2 capture technologies in power plants and energy-intensive industries.
The developed capture solutions were demonstrated in real environment (TRL 6) at 3 different demonstration sites. MOF4AIR aims to foster the uptake of CCUS technologies by delivering a TRL6-reliable solution that meets end-user needs, notably by reducing the energy penalty by more than 10%. The developed solutions are designed to be highly replicable, thanks to their relevance across a wide range of carbon intensive sectors and clusters, in particular through the project's Industrial Cluster Board (ICB) that includes industries from main CO2 emitting industrial sectors.
The developed capture solutions were demonstrated in real environment (TRL 6) at 3 different demonstration sites. MOF4AIR aims to foster the uptake of CCUS technologies by delivering a TRL6-reliable solution that meets end-user needs, notably by reducing the energy penalty by more than 10%. The developed solutions are designed to be highly replicable, thanks to their relevance across a wide range of carbon intensive sectors and clusters, in particular through the project's Industrial Cluster Board (ICB) that includes industries from main CO2 emitting industrial sectors.
A total of 27 MOFs produced in powder form at small scale were investigated and characterized through experimental measurements and theoretical simulations in terms of CO2 adsorption capacity, CO2/N2 selectivity, stability and regeneration in the presence of contaminants.
From this initial screening, five promising MOFs were selected based on their performances, stability, cost, environmental impact, and potential for large-scale production. These MOFs were scaled up to 500 g, shaped, fully characterized, and their adsorption properties were assessed. Two MOFs were further chosen for synthesis and shaping at 3-5 kg scale using different binders. Their adsorption properties were assessed through: (i) pure CO2 and N2 adsorption isotherm measurements; (ii) stability tests against water and other contaminants; (iii) breakthrough curve measurements.
Based on these results and additional considerations such as ligand and metallic precursor costs and availability, one MOF (MIL-160(Al)) was selected for testing in a VPSA process at both lab and industrial pilot scales. A second MOF was tested at lab-scale (MIL-120(Al)).
In an alternative configuration: MBTSA (Moving Bed Thermal Swing Adsorption), two MOFs (MIL-120(Al)) and Ni-MOF-74) have been tested.
Modelling confirmed the performance of the selected MOFs. For the MBTSA process, simulations demonstrated that the selected MOF could exceed the targets, achieving CO2 purity and recovery above 95% and 90%, respectively. Simulations with the second MOF in the VPSA process enabled the selection of the optimal bed/column configuration to meet performance targets.
Both MOFs were tested at lab-scale pilot units. Concerning MBTSA, first measurements were conducted, but further developments are still needed. Regarding the VPSA, the lab-scale pilot successfully validated the promising simulation-based predictions for the selected MOF. Additionally, operational requirements were highlighted for consideration in the industrial pilots.
From a demonstration point of view, 3 pilot plan configurations were studied based on site specific gas compositions. A techno-economic assessment (TEA) of the MOF based carbon capture system revealed a clear cost gap between PSA and TSA cycles. Moreover, a CAPEX estimation of the VPSA MOF-based CO2 capture process was also completed.
At the TCM site, the maximum CO2 purity achieved was 95.6 ± 3.6 % with a recovery of 91.1 ± 0.3 % and an energy consumption of 743 ± 12.2 kWh/ton, based on a 2-hour operating period representing 35 consecutive cycles. At the other sites, while the results were less promising, they remained consistent with the initial results at TCM site. Further improvements to the pilot are needed to reach similar performances across all sites.
A report on the legislative and regulatory conditions in participating countries, as well as on an EU level was done. In parallel, a survey was conducted, collecting over 1,750 answers from citizens (250 answers per participating country) as well as 25 interviews with national key-stakeholders. This study provided insights into social acceptance of CCS. The results were used to develop public engagement guidelines and communication scenarios, which considered the enhancement of public and stakeholder awareness concerning CCS-related aspects.
The Industrial Cluster Board is composed of various energy intensive industries in the main CO2 emissions sectors (cement, energy, chemistry, glass, refractories), and technology providers for CO2 capture or CO2 transportation. The industries followed the outcomes of the project, especially in terms of maturity and cost of the carbon capture solutions, mainly for possible transfer onto their industries.
To support dissemination, various communication tools were developed (website, social media posts, etc) and dedicated dissemination events were organised. Joint activities were also launched with other EU-funded H2020 projects.
From this initial screening, five promising MOFs were selected based on their performances, stability, cost, environmental impact, and potential for large-scale production. These MOFs were scaled up to 500 g, shaped, fully characterized, and their adsorption properties were assessed. Two MOFs were further chosen for synthesis and shaping at 3-5 kg scale using different binders. Their adsorption properties were assessed through: (i) pure CO2 and N2 adsorption isotherm measurements; (ii) stability tests against water and other contaminants; (iii) breakthrough curve measurements.
Based on these results and additional considerations such as ligand and metallic precursor costs and availability, one MOF (MIL-160(Al)) was selected for testing in a VPSA process at both lab and industrial pilot scales. A second MOF was tested at lab-scale (MIL-120(Al)).
In an alternative configuration: MBTSA (Moving Bed Thermal Swing Adsorption), two MOFs (MIL-120(Al)) and Ni-MOF-74) have been tested.
Modelling confirmed the performance of the selected MOFs. For the MBTSA process, simulations demonstrated that the selected MOF could exceed the targets, achieving CO2 purity and recovery above 95% and 90%, respectively. Simulations with the second MOF in the VPSA process enabled the selection of the optimal bed/column configuration to meet performance targets.
Both MOFs were tested at lab-scale pilot units. Concerning MBTSA, first measurements were conducted, but further developments are still needed. Regarding the VPSA, the lab-scale pilot successfully validated the promising simulation-based predictions for the selected MOF. Additionally, operational requirements were highlighted for consideration in the industrial pilots.
From a demonstration point of view, 3 pilot plan configurations were studied based on site specific gas compositions. A techno-economic assessment (TEA) of the MOF based carbon capture system revealed a clear cost gap between PSA and TSA cycles. Moreover, a CAPEX estimation of the VPSA MOF-based CO2 capture process was also completed.
At the TCM site, the maximum CO2 purity achieved was 95.6 ± 3.6 % with a recovery of 91.1 ± 0.3 % and an energy consumption of 743 ± 12.2 kWh/ton, based on a 2-hour operating period representing 35 consecutive cycles. At the other sites, while the results were less promising, they remained consistent with the initial results at TCM site. Further improvements to the pilot are needed to reach similar performances across all sites.
A report on the legislative and regulatory conditions in participating countries, as well as on an EU level was done. In parallel, a survey was conducted, collecting over 1,750 answers from citizens (250 answers per participating country) as well as 25 interviews with national key-stakeholders. This study provided insights into social acceptance of CCS. The results were used to develop public engagement guidelines and communication scenarios, which considered the enhancement of public and stakeholder awareness concerning CCS-related aspects.
The Industrial Cluster Board is composed of various energy intensive industries in the main CO2 emissions sectors (cement, energy, chemistry, glass, refractories), and technology providers for CO2 capture or CO2 transportation. The industries followed the outcomes of the project, especially in terms of maturity and cost of the carbon capture solutions, mainly for possible transfer onto their industries.
To support dissemination, various communication tools were developed (website, social media posts, etc) and dedicated dissemination events were organised. Joint activities were also launched with other EU-funded H2020 projects.
A list of potential MOFs was established. Better insight in MOF performances for carbon capture was achieved through the exploration of MOFs for VPSA and MBTSA-based CO2 capture under industrial-based operating conditions. In addition, an unprecedented understanding of the degradation mechanism of MOF under H2S exposure was gained. A reliable descriptor was identified to predict MOF stability under H2S exposure. These computational findings pave the way towards an accurate and fast prediction of MOFs stability without the need for extensive experimental exploration.
The scale-up and shaping of powdered MOF materials as alternative adsorbents for VPSA-based CO2 capture processes showed promising results. Tests on shaped materials prove their potential for use in adsorption processes.
One of the main outcomes of the project was the evaluation of carbon capture performance using promising MOF materials in demonstration units on three industrial sites. The promising results achieved with selected MOF materials under conditions that mirror those of industrial sites provide significant indicators for the potential of these processes using MOF materials.
The performance of these materials in real capture process was investigated through detailed process simulations. This allowed cost analysis and system sizing, offering valuable insights into the feasibility of MOF based CO2 capture technologies amines based processes.
The TEA and LCA conducted within the project contributed to establish MOF-based CO2 capture concept as a vital tool for achieving substantial emission reductions across the European industrial sector.
The scale-up and shaping of powdered MOF materials as alternative adsorbents for VPSA-based CO2 capture processes showed promising results. Tests on shaped materials prove their potential for use in adsorption processes.
One of the main outcomes of the project was the evaluation of carbon capture performance using promising MOF materials in demonstration units on three industrial sites. The promising results achieved with selected MOF materials under conditions that mirror those of industrial sites provide significant indicators for the potential of these processes using MOF materials.
The performance of these materials in real capture process was investigated through detailed process simulations. This allowed cost analysis and system sizing, offering valuable insights into the feasibility of MOF based CO2 capture technologies amines based processes.
The TEA and LCA conducted within the project contributed to establish MOF-based CO2 capture concept as a vital tool for achieving substantial emission reductions across the European industrial sector.