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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 2 - TERRA (Tandem Electrocatalytic Reactor for energy/Resource efficiency And process intensification)

Teaser

Summary

\"Problem/issue being addressed
A key element for energy and chemistry transformation to a low-carbon and sustainable future, and indicated as key action in the SPIRE Roadmap (Key Action 2.4), is to develop \"\"new ways of targeting energy input via electrochemical, light and ultrasound based systems will direct the reaction to the right target with less energy inputâ€. However, there are still very limited industrial processes based on electrocatalysis. The development of new concepts for industrial electrochemical processes is necessary, in particular in terms of catalytic electrodes and advanced electroreactors for chemical production. This is a key technology for (a) saving resources and energy, (b) process intensification, and (c) effectively introduce renewable energy in the value chain of production.

Why is it important for society?
The background knowledge developed within the projects are key aspects to this transformative energy and chemistry conversion towards a low-carbon and sustainable production, which largely substitute the use of fossil fuels (particularly to drive energy for the conversion processes) with renewable energy.

What are the overall objectives?
The main objective of the TERRA project is to obtain both MEG (mono ethylen glycol) and FDCA (2,5 dicarboxy furan) from sugars in a single and tandem electro-catalytic reactor (TER), with and adaptable technology, which allows control and tailoring of reactor performances by supplying renewable-based external electrical energy (e.g. wind or solar power). MEG and FDCA are monomers for the production of PEF (PolyEthylene Furanoate), a next-generation 100%-renewable plastic developed by partner AVT.
\"

Work performed

TERRA project is at the 2nd reporting Period (M36) of a four-years project. According to the project Gantt chart, activities in WP1 have to be completed. However, they were extended and will continue also in the 3rd period. For all the other WPs the activities were in line with the original Gantt chart, with a minor extension for Task 2.7.

A summary of the work performed and main results achieved is as follow:

WP1: Preparation and testing of electrodes. The activities related to Task 1.1 (Size-controlled nanoparticles and method of deposition) have been completed. Different series of novel stabilized nanoparticles have been prepared. Possibility to exploit novel preparation methodology in under analysis. Activities in Task 1.2 (Development lab-scale of catalytic electrodes) have led to the development of novel methodologies to prepare conductive electrodes, which possible exploitation is under investigation. The activity has been extended in support for Task 1.3 (Testing electrodes in small scale high P, T facility), where it was demonstrated the presence of an electrocatalytic effect and some interesting results, however still which do not meet expectation. The activity was extended. Therefore, activity in Task 1.4 (Scale-up anode electrodes for TER prototype) and Task 1.5 (Scale-up cathode electrodes for TER prototype) has been extended, but the starting scaled-up anode and cathode for TER experimentation have been defined.

WP2: Prototype TER design & development. The activity in this WP has been largely concluded. TER (Tandem Electrochemical Reactor) prototype design and related components has been completed, and construction of the prototype in progress. The optimal OHâ€”exchange membrane has been identified with interesting results which exploitability is under analysis. The cathode electrode with modulation function has been completed. The development of control methodologies on both reactor and electrode has been successful, with exploitability even out of the project under evaluation.

WP3: Prototype TER testing electrodes. Activity is well in line with planning. The cell has been manufactured and is ready to be assembled and tested. The TER prototype is nearly completed, and testing campaign planned.

WP4: Optimization of TER integration within full process. Also in this WP activities are in well alignment with planning. Most of these activities are planned for the 3rd period, but the block-flow diagram for the separation train process for both cathodic and anodic streams, based on the project specifications, has been drafted. The dimensions of the cell stack, which should meet the proposed productivities of FDCA and MEG in the final industrial process, giving information about the needed power consumption and the possible disposition, have been also estimated.

WP5: Process Assessment. The activities are scheduled mainly in the 3rd period. Initial LCA scope and boundaries have been identified.

WP6: Dissemination, exploitation, management & coordination. This support WP is in progress as expected.

The work made by TERRA beneficiaries is thus well in line, and in some part ahead, the scheduled activities. There are not significant deviations to remark, and expected Deliverables/Milestone are as scheduled, with just an agreed shift in some deliverables, and Milestones for which further activity has been planned.

Final results

Project impact

An Innovation Radar has been prepared to identify the maturity of innovations developed within the project. Four type of innovation are expected:

1. New type of electrocatalysts for the target combined electrocatalytic redox reactions and potentially applicable to other type of conversions of biobased platform molecules. The starting point was to adapt to electrocatalytic conditions catalysts for conventional thermal operations, but with the objectives to i) enhance the performances under operations suitable for the tandem electrocatalytic reactions, ii) develop improved 3D-type electrodes to enhance the reaction rates, iii) avoid the use of critical raw materials, and especially noble metals and iv) develop scalable methods for the preparation of the electrodes in industrial-relevant sizes. While in part these objectives have been achieved, still selectivity performances have to be improved.

2. Develop and set-up a prototype tandem electrocatalytic reactor for validation of tandem electrocatalytic reactions in biomass transformation under environmental-relevant industrial conditions. This prototype is in progress in line with expectations.

3. Develop an innovative methodology to decouple within some range the temperature of operations on the two sides of the electrocatalytic flow-reactor cell, to introduce a degree of flexibility in operations. This methodology has been developed in line with expectations.

4. Obtain feasibility indicators for the innovative technology of electrocatalytic production of tandem production of 2,5-dicarboxyfuran and ethylene glycol (monomers for PEF polymer production), demonstrating resource intensity and emissions reduction. This activity is still in progress, because the electrocatalysts/conditions need still to be improved.

In terms of expected impact of the project, the expected targets of determination of a reduction of at least 15% in i) process energy intensity and material resource use for relevant large volume industrial processes and ii) emissions compared to the present state of the art, are still in progress of evaluation. They will also allow analysing the other expected impact related to the improvements in the flexibility and productivity of industrial processes. The successful development of innovation 3 above is a good advance in this direction.