Periodic Reporting for period 3 - SunCoChem (Photoelectrocatalytic device for SUN-driven CO2 conversion into green CHEMicals)
Okres sprawozdawczy: 2023-05-01 do 2024-10-31
The strong dependence in Europe on carbon feedstock imports for energy and chemical manufacturing purposes and the upward trend in CO2 emissions compromises the competitiveness of the EU28 chemical industries. “Solar-driven Chemistry” brings an opportunity to an efficient use of resources and preservation of the environment and will become a driver for the transition to a new economic cycle in chemistry/energy production. SunCoChem addresses the need of the EU Chemical Industry for highly competitive and integrated solutions enabling the carbon-neutral production of energy and high-value chemicals from solar energy, H2O and CO2. The direct use of renewable energy to convert CO2 into chemicals is crucial for reducing the dependence on carbon feedstock imports and contribute to the reduction of the GHG. However, the development of efficient systems for the production of high-value chemicals from CO2 is limited by the low CO2 chemical reactivity. Photo-electrocatalysts (PEcats) and photo-electroreactors with increased efficiency and stability, which can operate in synergy or integrated with existing ones, can contribute to solve this challenge by developing competitive systems to convert sunlight, H2O and CO2 into valuable products. SunCoChem aims to develop a competitive and modular self-biased tandem photo-electrocatalytic reactor (TPER) to efficiently produce oxo-products from CO2, water and sunlight integrating CO2 capture and conversion in a single unit. The TPER will couple catalytic photo-assisted processes: (i) CO2 reduction and (ii) H2O oxidation, with non-photoassisted catalytic ones (iii) C-C bond formation by CO-carbonylation, in a novel device directly fed by CO2-exhausts. The single-unit “capture and conversion” architecture of the reactor enables the design of a self-biased device. This is key for obtaining the cost reduction, improved sunlight-to-chemicals energy conversion efficiency and improved stability targeted by SunCoChem. From the industrial and user point of view, the modular concept will allow a reduced control, simplified maintenance and a more compact and small system able to be integrated in different factory environments at various size scales and productivity targets. Together with the use of renewable energy, this device will open the possibility of a distributed chemistry production by the exploitation of a
standalone system having low operative costs (driven by renewable energy) for wastes valorisation.
standalone system having low operative costs (driven by renewable energy) for wastes valorisation.
SUNCOCHEM has produced the following results:
1. New molecular based-photo/electrocatalyst and photoelectrodes for solar-driven CO2 reduction to syngas
2. Scale-up of the synthesis of metal oxides nanoparticles
3. Scale-up of the preparation of the electrodes for CO2 reduction and O2 evolution
3.1. Scaled-up electrodes for CO2 reduction to syngas
3.2. Scaled-up photoelectrodes for water splitting and O2 evolution
4. High-voltage perovskite solar cells
5. Selective polysulfone membrane for CO2 Capturing (patented during the project)
6. Nanofibre-based Bipolar Membrane (BM) and fabrication method
7. Ionic liquids for CO2 capture, and reduction, their synthesis and purification
7.1 Ionic liquids for CO2 capture, synthesis and purification
7.2 Ionic liquids for electrochemical CO2 reduction.
8. New state-of-health monitoring tool based on Electrochemical Impedance Spectroscopy (EIS)
9. Scalable solar fuel device design that allows for high solar energy conversion efficiency (> 10%)
10. Photo-electrochemical reactor for the sustainable production of syngas from CO2
11. Social Impact Assessment methodology of new technology
12. Catalysts assessment through functional/structural investigations with operando techniques
13. Identification of new process for electrochemical conversion of CO2 to CO
These results have been disseminated throughout 45 events, 14 scientific publications, 9 magazine articles, 10 posters, and 4 workshops.
1. New molecular based-photo/electrocatalyst and photoelectrodes for solar-driven CO2 reduction to syngas
2. Scale-up of the synthesis of metal oxides nanoparticles
3. Scale-up of the preparation of the electrodes for CO2 reduction and O2 evolution
3.1. Scaled-up electrodes for CO2 reduction to syngas
3.2. Scaled-up photoelectrodes for water splitting and O2 evolution
4. High-voltage perovskite solar cells
5. Selective polysulfone membrane for CO2 Capturing (patented during the project)
6. Nanofibre-based Bipolar Membrane (BM) and fabrication method
7. Ionic liquids for CO2 capture, and reduction, their synthesis and purification
7.1 Ionic liquids for CO2 capture, synthesis and purification
7.2 Ionic liquids for electrochemical CO2 reduction.
8. New state-of-health monitoring tool based on Electrochemical Impedance Spectroscopy (EIS)
9. Scalable solar fuel device design that allows for high solar energy conversion efficiency (> 10%)
10. Photo-electrochemical reactor for the sustainable production of syngas from CO2
11. Social Impact Assessment methodology of new technology
12. Catalysts assessment through functional/structural investigations with operando techniques
13. Identification of new process for electrochemical conversion of CO2 to CO
These results have been disseminated throughout 45 events, 14 scientific publications, 9 magazine articles, 10 posters, and 4 workshops.
New concepts and advanced designs of PEcats, a TPER with an innovative approach involving 4 simultaneous processes. Expected results: Single TPER units and their enabling materials, The integration of TPER units and evaluation of potential impact vs. fossil-fuel based routes, demonstration of technical and economic feasibility, Evalutation of GHG emissions regarding commercial manufacturing by LCA, Assessment of increase of industrial competitiveness of the chemicals industry and Estimation of environmental and social benefits.
At TRL3, the system achieved a sunlight-to-chemical energy conversion efficiency of 4.6%, demonstrating stable syngas production. Integration of perovskite photovoltaic cells achieved a solar-to-fuel efficiency of 4–4.5%, with potential improvements identified in photoanode materials and light-harvesting techniques.
The project validates the technical feasibility of solar-driven CO2 reduction and suggests pathways for improvement through better reactor design and cost reductions. Economic viability could be enhanced by savings from rising CO2 tax allowances and lower electrode production costs, but long-term electrocatalyst stability remains a key challenge. The SunCoChem project continues to show promise for advancing PEC-based renewable chemical production technologies.
The TRL3 prototype demonstrated significant progress in system stability, maintaining stable syngas production for 200 hours with a CO:H2 ratio of ~4:1 under optimal conditions. The Cu2O/SnO2-based GDE achieved high Faradaic efficiency (CO ~85%) while mitigating challenges like GDE flooding through optimized pressure and flow rates. Integration with perovskite photovoltaic cells enabled a solar-to-fuel efficiency of 4–4.5%, showcasing scalability.
Operando characterization using EXAFS and X-ray fluorescence at BESSY-II provided insights into the catalyst’s elemental composition and oxidation state changes, aiding in material and operational optimization. Future integration of complementary techniques will further enhance performance and advance CO2 electrolysis technology toward industrial readiness, with a clear pathway to achieving long-term stability and economic feasibility.
The SunCoChem technology offers a sustainable alternative to fossil-fuel-based chemical production, particularly for oxo-products, with potential to become competitive after further improvements. Current challenges include low current density limitations of photocatalysts, leading to larger reactors and higher costs (CAPEX and OPEX). Transitioning to a PV+EC system could reduce syngas production costs by 70–75%.
The technology shows potential energy savings compared to traditional methods. At larger scales, energy consumption could be reduced by 11%, improving energy neutrality and lowering production costs, such as a 0.15 €/kg reduction for Limoxal.
From an environmental perspective, the project demonstrates reduced CO2 emissions and energy consumption. CO2 reductions of up to 50% are achieved for valeraldehyde and glycolic acid, and up to 90% for glycolic acid via electrochemical methods. Energy efficiency improvements are around 36% for valeraldehyde and 66% for glycolic acid. Limoxal shows lower reductions but follows a downward trend.
Future improvements could focus on optimizing reaction inputs or selecting materials with lower environmental impact, enhancing both energy efficiency and CO2 emission reductions.
At TRL3, the system achieved a sunlight-to-chemical energy conversion efficiency of 4.6%, demonstrating stable syngas production. Integration of perovskite photovoltaic cells achieved a solar-to-fuel efficiency of 4–4.5%, with potential improvements identified in photoanode materials and light-harvesting techniques.
The project validates the technical feasibility of solar-driven CO2 reduction and suggests pathways for improvement through better reactor design and cost reductions. Economic viability could be enhanced by savings from rising CO2 tax allowances and lower electrode production costs, but long-term electrocatalyst stability remains a key challenge. The SunCoChem project continues to show promise for advancing PEC-based renewable chemical production technologies.
The TRL3 prototype demonstrated significant progress in system stability, maintaining stable syngas production for 200 hours with a CO:H2 ratio of ~4:1 under optimal conditions. The Cu2O/SnO2-based GDE achieved high Faradaic efficiency (CO ~85%) while mitigating challenges like GDE flooding through optimized pressure and flow rates. Integration with perovskite photovoltaic cells enabled a solar-to-fuel efficiency of 4–4.5%, showcasing scalability.
Operando characterization using EXAFS and X-ray fluorescence at BESSY-II provided insights into the catalyst’s elemental composition and oxidation state changes, aiding in material and operational optimization. Future integration of complementary techniques will further enhance performance and advance CO2 electrolysis technology toward industrial readiness, with a clear pathway to achieving long-term stability and economic feasibility.
The SunCoChem technology offers a sustainable alternative to fossil-fuel-based chemical production, particularly for oxo-products, with potential to become competitive after further improvements. Current challenges include low current density limitations of photocatalysts, leading to larger reactors and higher costs (CAPEX and OPEX). Transitioning to a PV+EC system could reduce syngas production costs by 70–75%.
The technology shows potential energy savings compared to traditional methods. At larger scales, energy consumption could be reduced by 11%, improving energy neutrality and lowering production costs, such as a 0.15 €/kg reduction for Limoxal.
From an environmental perspective, the project demonstrates reduced CO2 emissions and energy consumption. CO2 reductions of up to 50% are achieved for valeraldehyde and glycolic acid, and up to 90% for glycolic acid via electrochemical methods. Energy efficiency improvements are around 36% for valeraldehyde and 66% for glycolic acid. Limoxal shows lower reductions but follows a downward trend.
Future improvements could focus on optimizing reaction inputs or selecting materials with lower environmental impact, enhancing both energy efficiency and CO2 emission reductions.