Carbon neutral manufacturing via on-site CO2 recycling.

The chemical industry needs to significantly decrease carbon dioxide (CO2) emissions in order to meet the 2050 carbon neutrality goal. Utilization of CO2 as a chemical feedstock for bulk products is a promising way to mitigate industrial emissions; however, CO2-based manufacturing is currently not competitive with the established petrochemical methods and its deployment requires creation of a new value chain. Here, we show that an alternative approach, using CO2 conversion as an add-on to existing manufactures, can disrupt the global carbon cycle while minimally perturbing the operation of chemical plants. Proposed closed-loop on-site CO2 recycling processes are economically viable in the current market and have the potential for rapid introduction in the industries. Retrofit-based CO2 recycling can reduce annually between 4 and 10 Gt CO2 by 2050 and contribute to achieving up to 50% of the industrial carbon neutrality goal

Towards an accelerated decarbonization of chemical industry by electrolysis

The transition towards carbon-neutral chemical production is challenging due to the fundamental reliance of the chemical sector on petrochemical feedstocks. Electrolysis-based manufacturing, powered by renewables, is a rapidly evolving technology that might be capable of drastically reducing CO2 emissions from the chemical sector. However, will it be possible to scale up electrolysis systems to the extent necessary to entirely decarbonize all chemical plants? Applying a forward-looking scenario, this perspective estimates how much energy will be needed to power full-scale electrolysis based chemical manufacturing by 2050. A significant gap is identified between the currently planned renewable energy expansion and the energy input necessary to electrify the chemical production: at minimum, the energy required for production of hydrogen and electrolysis of CO2 corresponds to > 50% of all renewable energy that is planned to be available. To cover this gap, strategies enabling a meaningful reduction of the energy input to electrolysis are being discussed from the perspective of both a single electrolysis system and an integrated electro-plant. Several scale-up oriented research priorities are formulated to underpin timely development and commercial availability of described technologies, as well as to explore synergies and support further growth of the renewable energy sector, essential to realize described paradigm shift in chemical manufacturing

Techno-economic assessment of emerging CO2 electrolysis technologies.

Recycling of waste CO2 to bulk chemicals has a tremendous potential for the decarbonization of the chemical industry. Quantitative analysis of the prospects of this technology is hindered by the lack of flexible techno-economic assessment (TEA) models that enable evaluation of the processing costs under different deployment scenarios. In this protocol, we explain how to convert literature data into metrics useful for evaluation of the emerging electrolysis technologies, derive TEA models, and illustrate their use with a CO2-to-ethylene example. For complete details on the use and execution of this protocol, please refer to Barecka et al. (2021a)

Energy-Efficient Ethanol Concentration Method for Scalable CO2 Electrolysis

Electrosynthesis of ethanol from carbon dioxide (CO2) is a promising route to generate a sustainable fuel and a convenient feedstock for chemical manufacturing. While significant progress has been achieved in boosting the selectivity of CO2 to ethanol, the subsequent ethanol separation remains a bottleneck, which prevents leveraging the laboratory results into large-scale systems. Here we report vacuum membrane distillation as a method that efficiently concentrates dilute ethanol streams produced by CO2 electrolysis (CO2R), yielding up to ∼40 wt% ethanol in pure water. In our design considerations, we include previously underappreciated thermodynamic properties of the catholyte (salting-out effect) and propose strategies allowing a more precise estimation of energy inputs to the separation processes. Our work provides the basis for the detailed design of complex systems which integrate flow reactors and liquid separations and supports scaling of the systems previously considered not optimized for industrial use

Low cost 3D printable flow reactors for electrochemistry

Transition to carbon neutrality requires the development of more sustainable pathways to synthesize the next generation of chemical building blocks. Electrochemistry is a promising pathway to achieve this goal, as it allows for the use of renewable energy to drive chemical transformations. While the electroreduction of carbon dioxide (CO2) and hydrogen evolution are attracting significant research interest, fundamental challenges exist in moving the research focus toward performing these reactions on scales relevant to industrial applications. To bridge this gap, we aim to facilitate researchers' access to flow reactors, which allow the characterization of electrochemical transformations under conditions closer to those deployed in the industry. Here, we provide a 3D-printable flow cell design (manufacturing cost $6,000). The proposed design and detailed build instructions allow the performance of a wide variety of chemical reactions in flow, including gas and liquid phase electroreduction, electro(less)plating, and photoelectrochemical reactions, providing researchers with more flexibility and control over their experiments. By offering an accessible, low-cost reactor alternative, we reduce the barriers to performing research on sustainable electrochemistry, supporting the global efforts necessary to realize the paradigm shift in chemical manufacturing

Prioritizing Mentorship as Scientific Leaders

Prioritizing Mentorship as Scientific Leader