ELCO2SYN

In the ElCO2Syn project, VITO and imec envisage the upscaling and demonstration of CO₂ and H₂O electroreduction into syngas. The technical and economic viability will be proven at 5 kW scale, using cutting edge Ag-nanomesh electrodes. The success relies mainly on the cathode upscaling and design/construction of a pressurized stack and balance-of-plant. This last will reveal the superior characteristics of Ag-nanomeshes to converting CO₂ to CO and produce H₂ in a one-step process. ElCO2Syn represents an electrified approach to reduce the carbon footprint of syngas by 70% and paves the way for de-fossilized, viable chemical processes.

The first objective is the optimization and upscaling of uniform monolithic Ag-based nanostructured electrodes, to achieve improved CO₂transport, and reach CO production rates of 200 mA/cm2 at 20 bar. Furthermore the ambition is to increase the electrode size to >200 cm². The upscaled Ag-nanomesh will applied in a membrane electrode assembly (MEA), suitable for long-term testing in single cells and short stack. The stack will be tested in a dedicated and optimized electrolyzer system,  which is able to fully exploit the electrode’s potential at a design pressure of 20 barg, at variable loads and CO₂ feed concentrations. During this 1000 h field test, the performance will be evaluated continuously with pure CO2 and point source streams from high CO2 emitters such as steel, cement or fossil-based power plants. Finally, the economic and climate impacts are evaluated and the process benchmarked with state-of-the-art and emerging technologies, in order to properly frame ElCO2Syn’s contribution to the specific MOT3 goals and KPIs.

The project will deliver an individual and integrated solutions for CO2 capture and Utilization via 1. demo electrolysers for CO2 valorisation and syngas production, 2. materials for the electrolysis reactor: membranes, electrodes and (electro)catalysts and 3. a novel production route for chemicals, fuels and plastics, that relies on sustainable syngas production. An operational demo will be delivered, and serve as blueprint for larger equipment, after which the integration of modular electrolysers in an industrial environment (demo hosting) is envisaged. The composition of syngas output and its use downstream should be evaluated by the end users. At the same time, technology suppliers would focus on upscaling of the 5 kW electrolyser towards the 100 kW and MW range, while material producers contribute by development of key electrolyser components.

The syngas can be used in different pathways towards chemicals, fuels and plastics, next to other direct applications of CO. The contribution of ElCO2Syn will be:

• >70 % reduction in syngas’ CO2 footprint by electrification (MOT3 KPI1).
• First potential impact in the production of CCU-based molecules in Flanders, which is even more pronounced if biogenic or atmospheric CO2 is applied as feedstock.
• A rather low CO2 avoidance cost that contributes to an economically justifiable conversion of captured CO2 as a raw material in the Flemish industry (MOT3 KPI3).