SHAPE

Introduction 

Graphite and hydrogen are essential for the clean energy transition, yet their current production methods are highly carbon-intensive. Synthetic graphite is typically made from petroleum coke at temperatures above 3000 °C, emitting up to 13.8 kg CO₂ per kilogram produced. Similarly, conventional hydrogen production relies on fossil-based steam methane reforming. SHAPE addresses these challenges by developing a breakthrough process that converts biogas—a renewable feedstock—into battery-grade graphite and low-carbon “turquoise” hydrogen, powered entirely by renewable electricity. 

Goal 

SHAPE aims to design and demonstrate an electrified catalytic process that transforms biogas into two high-value products: high-purity graphite and low-carbon hydrogen. By integrating thermal energy storage, the technology will operate flexibly with intermittent renewable power, paving the way for a scalable, carbon-neutral solution for critical materials and clean energy. 

Approach 

SHAPE will develop novel iron-based catalysts and an innovative swirling fluidized bed reactor combined with a thermal energy storage system. This integrated design enables continuous operation, efficient heat management, and mechanical catalyst regeneration without CO₂ emissions. The process will tolerate biogas streams with up to 40% CO₂, reducing costly upgrading steps. Advanced characterization will ensure graphite meets stringent quality standards for applications such as lithium-ion batteries and fuel cells. 

Expected impact and valorization 

By replacing energy-intensive synthetic graphite production and fossil-based hydrogen routes, SHAPE offers a disruptive pathway to negative CO₂ emissions: up to 16 Mt CO₂-equivalent per year for graphite and 4.3 Mt for hydrogen. The technology strengthens Europe’s supply of critical raw materials, reduces dependency on imports, and supports the electrification of high-temperature processes. Valorization will occur through industrial partnerships across the biogas, chemical, and battery sectors, with follow-up projects targeting scale-up and commercialization by 2040–2045.