Periodic Reporting for period 3 - eCOCO2 (Direct electrocatalytic conversion of CO2 into chemical energy carriers in a co-ionic membrane reactor)
Berichtszeitraum: 2022-05-01 bis 2023-10-31
Policies to reduce greenhouse gas (GHG) emissions can impact carbon-intensive industrial sectors, leading to loss of competitiveness and employment. Current multistage CO2 conversion technologies using renewable electricity to produce fuels suffer from low energy efficiency and need large CAPEX. eCOCO2 combines molecular catalysis and process intensification to provide a novel, efficient, CO2 conversion technology, thereby, reducing carbon emissions.
eCOCO2 aimed to set up a CO2 conversion process using renewable electricity and water steam to produce synthetic jet fuel with balanced hydrocarbon distribution to meet aviation specifications. The concept is based on a tailor-made multifunctional catalyst integrated into a co-ionic electrochemical cell, enabling in-situ electrolysis and delivery of protons to the hydrocarbon synthesis reaction side, while water removal via oxide ion transport to the steam side provides additional H2. This process can lead to a breakthrough product yield and efficiency for chemical energy storage from electricity, specifically CO2 per-pass conversion >85%, energy efficiency >85% and net specific demand <6 MWh/t CO2 as demonstrated in the project from the techno-economic assessment. Development of eCOCO2 principles can lead to a compact, modular-flexible process. Thus, process operation and economics could be adjusted to renewable energy fluctuations. As a result, this technology has the potential to store more energy per processed CO2 molecule and reduce GHG emissions per jet fuel tone produced from electricity at a substantially higher level.
The project aimed to demonstrate the technology in an existing modular prototype rig that integrates tubular intensified electrochemical reactors.
eCOCO2 aimed to set up a CO2 conversion process using renewable electricity and water steam to produce synthetic jet fuel with balanced hydrocarbon distribution to meet aviation specifications. The concept is based on a tailor-made multifunctional catalyst integrated into a co-ionic electrochemical cell, enabling in-situ electrolysis and delivery of protons to the hydrocarbon synthesis reaction side, while water removal via oxide ion transport to the steam side provides additional H2. This process can lead to a breakthrough product yield and efficiency for chemical energy storage from electricity, specifically CO2 per-pass conversion >85%, energy efficiency >85% and net specific demand <6 MWh/t CO2 as demonstrated in the project from the techno-economic assessment. Development of eCOCO2 principles can lead to a compact, modular-flexible process. Thus, process operation and economics could be adjusted to renewable energy fluctuations. As a result, this technology has the potential to store more energy per processed CO2 molecule and reduce GHG emissions per jet fuel tone produced from electricity at a substantially higher level.
The project aimed to demonstrate the technology in an existing modular prototype rig that integrates tubular intensified electrochemical reactors.
Throughout the project, significant advancements were made. A comprehensive evaluation of new composite electrolytes integrating various proton conducting and oxide ion conducting phases was made generating knowledge on stability, conductivity and hydration properties of these compounds. Electrode materials were optimised to operate at T ≤ 450ºC by adjusting their composition and microstructure. Hybrid catalysts for direct CO2 reduction to jet fuel hydrocarbons via the reverse water gas shift and Fischer-Tropsch synthesis route were successfully developed for operation at 400ºC. A two-step process was also validated to match the operation of the catalysts and the electrochemical cell, coupling direct CO2 reduction with an oligomerization step to produce jet fuel with higher yields and adjusted aromatics content.
The project expanded know-how on producing tubular cells with various BZCY-based electrolyte compositions and tubular cells integrating oxide ion electrolytes. Microwave sintering protocols were also developed to densify BZCY based electrolytes.
The validation phase focused on demonstrating operation of electrochemical reactors in pressurized operation up to 30 bar, using single tubular cells. This resulted in the successful electrochemical validation of complete cells with different electrolyte stoichiometries, demonstrating methanation and the co-electrolysis reaction to produce syngas under targeted conditions. The prototype testing phase involved adapting a multi-tube reactor for operation under eCOCO2 conditions, emphasising automation and safety aspects. Successful commissioning of the reactor and tests using protonic tubular cells were conducted.
Concurrently, processes within targeted industries were identified and defined in specific scenarios within the process engineering phase. Detailed CO2/steam feed flow characterization, flow diagrams, and potential integration assumptions for eCOCO2 technology were developed. The screening methodology identified key cost drivers for CAPEX and OPEX, indicating that further technology developments could enhance economic viability. Life Cycle Assessment indicated climate change reductions when using renewable electricity in the studied industrial scenarios. The societal perception studies conducted indicated a growing acceptance of CO2-based aviation fuel, positive attitudes towards innovative solutions for addressing climate change, and a preference for CO2-based fuels over conventional alternatives.
It is also worth highlighting the high participation in the project's communication channels, over 100 communications at events, 8 scientific publications, training activities, and academic initiatives. Finally, the results of eCOCO2 underline the viability and strategic significance of the proposed technological scale-up, emphasizing modular design, continuous reactor operation, thermal integration and strategic process integration as key elements for achieving efficient CO2 emission reduction in industrial sectors.
The project expanded know-how on producing tubular cells with various BZCY-based electrolyte compositions and tubular cells integrating oxide ion electrolytes. Microwave sintering protocols were also developed to densify BZCY based electrolytes.
The validation phase focused on demonstrating operation of electrochemical reactors in pressurized operation up to 30 bar, using single tubular cells. This resulted in the successful electrochemical validation of complete cells with different electrolyte stoichiometries, demonstrating methanation and the co-electrolysis reaction to produce syngas under targeted conditions. The prototype testing phase involved adapting a multi-tube reactor for operation under eCOCO2 conditions, emphasising automation and safety aspects. Successful commissioning of the reactor and tests using protonic tubular cells were conducted.
Concurrently, processes within targeted industries were identified and defined in specific scenarios within the process engineering phase. Detailed CO2/steam feed flow characterization, flow diagrams, and potential integration assumptions for eCOCO2 technology were developed. The screening methodology identified key cost drivers for CAPEX and OPEX, indicating that further technology developments could enhance economic viability. Life Cycle Assessment indicated climate change reductions when using renewable electricity in the studied industrial scenarios. The societal perception studies conducted indicated a growing acceptance of CO2-based aviation fuel, positive attitudes towards innovative solutions for addressing climate change, and a preference for CO2-based fuels over conventional alternatives.
It is also worth highlighting the high participation in the project's communication channels, over 100 communications at events, 8 scientific publications, training activities, and academic initiatives. Finally, the results of eCOCO2 underline the viability and strategic significance of the proposed technological scale-up, emphasizing modular design, continuous reactor operation, thermal integration and strategic process integration as key elements for achieving efficient CO2 emission reduction in industrial sectors.
eCOCO2 technology combines CO2 reduction and steam electrolysis in a process of unprecedented high efficiency and lower production costs. Current multistage CO2 conversion technologies using renewable electricity to yield fuels suffer from low energy efficiency and require large CAPEX. Techno-economic analysis of eCOCO2 concept has shown benefits of integrating this technology in selected applications: reducing energy expenses (due to the high energy efficiency) and capital investment (due to process intensification).
It can be said that eCOCO2 not only advances technological solutions for CO2 conversion but also holds promise for economic growth, industrial innovation, and environmental sustainability. eCOCO2 has contributed to i) the introduction of new solutions for CO2 conversion into valuable products by the development of multi-functional catalysts used in electrochemical protonic reactors and /or in catalytic routes; ii) the new cell designs and successful production of scalable proton-conducting and oxygen-conducting cells; and iii) the contribution to a circular economy, assessing the carbon footprint and proposing efficient solutions for CO2 reuse to energy intensive industries. Similarly, it demonstrated higher CO2 conversion rates and higher product yields, showing improvements in energy efficiency.
Furthermore, the project results in relation to CO2-based jet fuel production have wider societal implications, indicating a positive perception and openness towards sustainable aviation fuels. The favourable uptake levels suggest a potential contribution to reducing carbon emissions in the aviation industry, in line with global efforts against climate change. Acceptance varies depending on factors such as environmental awareness, education and regional differences, underlining the importance of tailored communication strategies. People's willingness to learn about sustainable innovations could foster greater interest in and demand for sustainable practices, contributing to a more resilient and sustainable society.
Acceptance, especially for novel products, is not guaranteed, and reactions go beyond end products to production processes, technical components and materials. It is crucial to conduct acceptance studies early in the technological process to inform designers about possible negative reactions, thus allowing the selection of other production routes.
It can be said that eCOCO2 not only advances technological solutions for CO2 conversion but also holds promise for economic growth, industrial innovation, and environmental sustainability. eCOCO2 has contributed to i) the introduction of new solutions for CO2 conversion into valuable products by the development of multi-functional catalysts used in electrochemical protonic reactors and /or in catalytic routes; ii) the new cell designs and successful production of scalable proton-conducting and oxygen-conducting cells; and iii) the contribution to a circular economy, assessing the carbon footprint and proposing efficient solutions for CO2 reuse to energy intensive industries. Similarly, it demonstrated higher CO2 conversion rates and higher product yields, showing improvements in energy efficiency.
Furthermore, the project results in relation to CO2-based jet fuel production have wider societal implications, indicating a positive perception and openness towards sustainable aviation fuels. The favourable uptake levels suggest a potential contribution to reducing carbon emissions in the aviation industry, in line with global efforts against climate change. Acceptance varies depending on factors such as environmental awareness, education and regional differences, underlining the importance of tailored communication strategies. People's willingness to learn about sustainable innovations could foster greater interest in and demand for sustainable practices, contributing to a more resilient and sustainable society.
Acceptance, especially for novel products, is not guaranteed, and reactions go beyond end products to production processes, technical components and materials. It is crucial to conduct acceptance studies early in the technological process to inform designers about possible negative reactions, thus allowing the selection of other production routes.