KETs Impact: CO2 as a raw material – The Carbon4PUR Project

The recent SusChem White paper ‘Impact: Key Enabling Technologies (KETs) in Horizon Europe’ included a number of success stories highlighting publicly funded innovation involving KETs and the SusChem News blog is featuring a selection of these fruitful 'SusChem inspired' initiatives.

KETs are technologies selected for their ability to address global challenges, support the development of new products, and stimulate economic growth.

Sustainable chemistry is essential to the technological advance of KETs including advanced materials, advanced manufacturing technologies, industrial biotechnology, micro and nanoelectronics, nanotechnology and photonics. SusChem's key enabling technologies provide the critical building blocks for the solutions needed to achieve a sustainable low carbon circular economy. You can find out more here.

Our third highlighted success story features the use of CO2 as an alternative feedstock for the chemical industry. The article highlights a number of projects undertaken by Covestro with German government funding and European projects enCO2re, funded by the European Institute for Innovation and Technology (EIT), and the SPIRE Horizon 2020 project Carbon4PUR that looks to turn industrial waste gases (mixed CO/CO2 streams) from energy intensive steel mills into intermediates for polyurethane plastics used for rigid foams, building insulation, coatings and other consumer products.

Carbon dioxide as a raw material for plastics

Innovative process technology reduces petroleum use

Availability of combined public funding appears crucial to mitigate the high risk of early research and complement own expertise with partnerships along the value chain.

Covestro has been working for many years on the development of technologies to turn CO2 into a valuable resource and for its implementation in making polymers. This “waste” gas is an alternative source of carbon and can substitute fossil raw materials and be used to make building blocks for polyols – a key starting material for polyurethanes. The first breakthrough came when Covestro’s researchers discovered the right catalyst and process for an economically and ecologically efficient reaction. As a first product stemming from the newly developed technology, CO2-based polyols for flexible foam found in mattresses and upholstered furniture are already on the market. Other kinds of products for further applications are under development – for example to obtain chemical building blocks and polymer intermediates for rigid foams and coatings to be applied in building insulation and coatings. The new technology, currently under investigation, is expected to reach Technology Readiness Level (TRL) 6 by 2020. The next step, after 2022, might be building an industrial plant for the production of CO2-based chemicals at large scale.

How was the breakthrough innovation achieved?

Partnerships between research-based companies and application-oriented research organisations along the value chain are the key to success. With a portfolio of collaboration projects, expertise can be built up starting from low TRL levels. At Covestro, first samples of CO2-based polyols were produced on a mini-plant scale after only three years. Five years later, a demonstration plant with the capacity of 5,000 metric tons/year went on stream. To reach high impact, private investments have been complemented by public funding obtained from both German national sources and EU funds. 

Impact

With the new technology, the use of petroleum can already be reduced by up to 20% in the case of CO2-based foams and 25% in case of elastomers. Also, the carbon footprint is better than with conventional processes. In the latest project, substantial reduction of process energy consumption is also expected by as much as 70%. This is an important contribution to sustainability and achieving the circular economy and helps to close the CO2 loop. 

More information
Carbon4PUR - Turning industrial waste gases (mixed CO/CO2 streams) into intermediates for polyurethane plastics for rigid foams/building insulation and coatings (Horizon 2020/ SPIRE GA 768919)

enCO2re flagship project CroCO2PETs (Climate-KIC / European Institute of Innovation and Technology)

r+impuls Production Dreams (German Federal Ministry of Education and Research FKZ 033R150)

CO2Plus Dream Resource (German Federal Ministry of Education and Research FKZ 033RC002)

MatRessource Dream Polyols (German Federal Ministry of Education and Research FKZ 03XP0052)

Read the SusChem White Paper ‘Impact: Key Enabling Technologies (KETs) in Horizon Europe’

Introducing new SusChem Chair: Dr. Markus Steilemann

The European Technology Platform for Sustainable Chemistry (SusChem) Board has announced that Dr. Markus Steilemann is its new Chair, succeeding Dr. Klaus Sommer who served six years in this position.

Dr. Steilemann (above), who will lead the Board in managing SusChem’s strategy and activities, brings valuable expertise in innovation and management. He is the Chief Commercial Officer of material producer Covestro and - since 2015 - a member of the Covestro Board of Management. His responsibilities encompass all commercial functions, including innovation and the company’s three segments: Polyurethanes, Polycarbonates and Coatings, Adhesives and Specialties.

Dr. Steilemann holds a PhD in Chemistry and started his career at the Bayer Group, where he moved to various management positions at the former Bayer MaterialScience, which has become Covestro in 2015.

SusChem beyond 2020

“I am honoured to take the leadership of SusChem at a time when new strategies in the European research and innovation policy, missions and funding beyond 2020 are being designed,” Dr. Steilemann said, adding that SusChem is already working together with the European Commission on the preparation of the next EU Framework Programme after Horizon 2020.

“The role of the chemical industry should feature prominently in it as the crucial link between scientific breakthroughs and societal challenges for delivering impact. The disruptive technologies needed to transform our economy and society towards a more sustainable future will be enabled through chemistry,” Dr. Steilemann underlined.

A driving force for KETs

SusChem is a driving force behind the EU strategy for Key Enabling Technologies. Under Dr. Sommer’s leadership its strategy was refocused and its role for accelerating innovation reinforced. 

SusChem now includes 14 national technology platforms, connecting national and regional sustainable chemistry initiatives and developing synergies with EU policy and funding schemes. 

Dr. Sommer (pictured right) played a decisive role in the discussions, initiated by SusChem, which lead to the establishment of the SPIRE Public-Private Partnership in the process industries and of which he was also Chair of the Board of Management.

Premiere for a New Raw Material: CO2

Today (17 June) Covestro has opened a new production plant in Dormagen, Germany that uses an innovative process that will help cut the use of fossil fuel based feedstock by partially replacing it with carbon dioxide (CO2). For the first time, Covestro is using CO2 to produce plastics on an industrial scale. The production plant for this innovative foam component made with 20% CO2 is at Covestro's Dormagen site near Cologne in Germany. The new process saves a proportional amount of the traditional oil-based raw material, thus making a contribution to sustainability that Covestro believes offers considerable potential. 

SusChem is also supporting research and innovation into the further utilisation of CO2 as a valuable feedstock for chemicals and fuels as part of a broad approach to enabling the circular economy and industrial symbiosis. The use of CO2 as a renewable feedstock features in SusChem's recent Strategic Innovation and Research Agenda (SIRA) and was discussed at our Stakeholder meeting on 16 June. 

SusChem believes that the utilisation of CO2 as a feedstock by the European chemical industry could be a key solution to reducing use of fossil fuels, reducing the EU’s dependence on imports of fossil resources and improving the security of supply of carbon feedstock. Exploiting sustainable carbon resources, such biomass and CO2 will enable production of more sustainable chemicals and materials with lower net CO2 emissions. 

This shift will result in reduced utilisation of fossil resources, and take industry a step closer to a true circular economy.

“We have to change the way we look at CO2, and we will. Using it as an alternative source of raw materials is a solution to some of the biggest challenges of our time – finding a replacement for finite fossil resources such as oil and gas and closing material cycles. Thanks to our innovative process and the launch of our production operations in Dormagen, we see ourselves as a pioneer in this area – true to our vision ‘To make the world a brighter place’,” said Covestro CEO Patrick Thomas at the opening ceremony. 

Long-term perspective

“This method of using carbon dioxide as a raw material is an important step as we move toward a sustainable future. The German Federal government is promoting the use of CO2 as a raw material in order to expand the chemical industry’s raw materials basis and open new avenues to sustainability,” emphasised Thomas Rachel, Parliamentary State Secretary from the German Federal Ministry of Education and Research. The German government supported Covestro’s technology financially in the research and development phase.

Professor Ernst Schmachtenberg, Rector of RWTH Aachen University, added: “Making efficient use of the carbon dioxide molecule, which is normally slow to react, is a real scientific and technical challenge. We have made a breakthrough by combining application-centric basic research with research-based industrial practices.”

Covestro scientists worked hand-in-hand with experts from the CAT Catalytic Center in Aachen – a research institute operated jointly with RWTH – to find the right catalyst that would make the chemical reaction with CO2 possible. A team under researcher Dr. Christoph Guertler (pictured left) discovered the right catalyst to enable the use of CO2 for plastics production.

For mattresses and upholstery

In Dormagen, Covestro is now using carbon from CO2 to manufacture a new type of polyol. These are core building blocks for polyurethane foam – a versatile material that is used in many industries around the world and that we encounter throughout our daily lives. The carbon dioxide is chemically bound into the material.

The company has invested some EUR 15 million in the new plant, which has an annual production capacity of 5 000 metric tons. The CO2 used is a waste product from a neighbouring chemical company - a great example of the sort of value chains that will be the basis of a future circular economy. 

The new CO2-based polyol has been engineered initially for flexible polyurethane foam intended for use in mattresses and upholstered furniture. In terms of quality, the foam achieves at least the same high standards as conventional material produced using only petrochemical raw materials. 

Environmentally friendly processes

By eliminating the use of crude oil and saving the energy otherwise used to process that oil, the method is more environmentally friendly than conventional production processes. Thanks to the catalyst and the considerable energy contained in the remaining content of petrochemical raw materials, no additional energy needs to be expended to make the low-reactivity CO2 react.

If the new CO2-based products are received as warmly as is hoped, Covestro can envisage significant production expansion. In addition to flexible foam, the company is also working on manufacturing many other plastics with carbon dioxide. Its vision is to one day largely dispense with crude oil in plastics production.

You can read more about the opening of the plant and the Covestro DREAM process here. 

Image credit: All images used in this article are (c) Covestro

Wanted: Ideas for re-using CO2

The Climate-KIC flagship programme EnCO2re (Enabling CO2 re-use) working for sustainable production and circular economy has launched its first open call for proposals to the public. This call is aimed at projects that will begin in September (or earlier) and produce meaningful results within 2016. The selection process is two part, but to take part you need to be quick as the first submission deadline is 27 May.

EnCO2re will add new workstreams in the second half of 2016 and is looking for:

• Projects related to any element of the CO2 value chain, from capture to conversion, and logistics
• Organisations that bring industrial and/or start-up perspectives with pathways to commercialisation
• Technologies and demonstrations for CO2-based products, especially intermediates and polymers
• Business-model innovations that support the development of a CO2 re-use value chain
• Other innovations, including incentives, that advance progress toward large-scale re-use of CO2

Two phase
The call is structured in two phases. The first phase requests a short Expression of Interest using a common template by 27 May.  In the EnCO2re Call profile you can find more details on the call.  You will find some help and guidelines for completing the EoI here.  Successful ideas that meet the call interests and requirements will be invited soon after 10 June to submit a full proposal by 1 July.

Because the programme is an open innovation programme and would like to be as inclusive as possible, all parties interested in joining enCO2re are urged to submit an EoI, even if they do not have a project that can begin in 2016.  All submissions should be emailed to Ted Grozier at Climate-KIC.

About EnCO2re
EnCO2re is an innovation and market development programme for CO2 re-use. Their vision is a balanced and prosperous market for re-used CO2, beginning with a focus on polymers and chemical intermediates. Their ambition is large-scale CO2 re-use through the establishment of a CO2 value chain.

EnCO2re was co-initiated by Climate-KIC and industry partner Covestro, forming a consortium of 12 European partners from industry and research sectors. The programme has a comprehensive approach towards CO2 re-use and comprises activities in technology development, product development, technology acceptance, ecological assessments and market development.

EnCO2re is pronounced like the French word encore, meaning “again,” in reference to the re-use of CO2 the programme aims to enable.

The initial open innovation consortium consists of 12 European partners: Bayer Technology Services, Chalmers University of Technology, Covestro, Imperial College London, Johanneberg Science Park, Engie Labs, Mines ParisTech, RWTH Aachen, TU Berlin, TU Delft, University of Copenhagen and Wuppertal Institut.

Taking a Leaf out of Nature’s Book

Mimicking photosynthesis may be the key to unlocking a future energy scene dominated by renewables. But nature’s simple process still holds many secrets. In light of the high-level Cefic breakfast debate on advanced materials and energy challenges that took place at the 7th European Innovation Summit, we asked science writer Ben Skuse to delve into how breakthroughs in materials may help resign fossil fuels to the past through the development of novel technologies and perhaps – eventually – artificial leaves.

The development of novel processes using waste carbon dioxide - up to and including the ultimate goal of artificial photosynthesis - feature in the SusChem Innovation and Research Agenda. 


Photosynthesis is a wonder of nature. It transforms energy from the light that the Sun bathes the Earth in to energy‐rich sugars. Simply put, it takes carbon dioxide and water, and converts them to glucose and oxygen.

There are two stages to this process. The first – water splitting – converts water into oxygen and a protein. In the next step, the protein reacts with CO2 to produce biomass. So far, scientists have only managed to master the former, splitting water using electrolytic processes to create hydrogen gas instead of biomass. But even on its own this feat was a huge achievement, paving the way for hydrogen fuel cell vehicles being actively commercialised today by the likes of Daimler and Toyota, and for the power industry taking hydrogen energy storage seriously as an option to deal with intermittent renewable power generation.

Hydrogen has some limitations
While hydrogen has one of the highest energy densities of any fuel, it is also the lightest of all elements. This means its storage requires very large volumes or very high pressures, resulting in issues of safety. Furthermore, the high cost of developing infrastructure and the energy intensity of the water splitting process offer sceptics a strong argument that hydrogen may not be the future for energy storage or the automotive industry.

“Hydrogen has some limitations,” confirms Sophie Wilmet, Cefic Innovation Manager. Sophie believes CO2 conversion technologies might provide a good alternative for large-scale storage of renewable energy using existing infrastructure. “CO2 can be used to address the energy storage challenge brought about by the rise in renewables, as well as for alternative fuels for transport.”

Carbon as a resource
Although not using direct photoconversion of CO2, a number of technologies are being actively explored to transform CO2 from a reviled waste product to a useful resource, as Sophie explains: “From CO2 you can produce basic and added-value chemicals”.

For example, a process co-developed by RWTH Aachen University and Covestro, formerly Bayer MaterialScience, has led to the construction of a plant that will be opened in 2016 in Dormagen, Germany, capable of producing up to 5000 metric tons per year of polyols, a polyurethane intermediate. About 20% of the content of the polyols will be from waste CO2 captured from a nearby ammonia plant, with the final material a flexible foam for mattresses.

Another innovator is Icelandic company Carbon Recycling International (CRI), whose renewable methanol reduces carbon emissions by more than 90% compared to fossil fuels. The fuel is produced from CO2 and hydrogen that comes from renewable sources of electricity. The world's first liquid renewable transport fuel production facility from non-biological sources of energy, CRI has a 4000 metric ton per year production capacity.

Further novel ideas include using large volumes of waste CO2 from industrial processes to produce syngas (BASF);  converting waste gases from iron and steel mills into ethanol and other important chemicals, such as acetic acid, acetone, isopropanol, n-butanol or 2,3 butanediol (Siemens/LanzaTech); and creating a closed carbon cycle using renewable energy, CO2 and water to provide sustainable fuels for vehicles and decentralised electricity generation (sunfire).

Mimicking nature
Capable of absorbing CO2 at the very low concentrations (400 parts per million) found in the air, absorbing energy from low-photon count sunlight, and photosynthetic cell self-repair, the ‘technology’ within plants is far more advanced than anything devised by humankind so far.
However, with aeons to perfect the technique, it comes as something of a surprise that energy conversion in plants is not actually particularly efficient: “For most plants the photosynthetic and storage efficiency is an average of 1%,” explains Dr Junwang Tang, Reader in Energy from University College London, UK.  Why is photosynthesis so inefficient? “The natural process is capable of utilising 100% of photons but green plants give up that potential to protect themselves – nature doesn’t need so much energy.”

As a result, if society were to mimic photosynthesis unaltered, there would not be enough land on Earth to cycle the carbon required for a sustainable future. Instead, researchers are aiming to enhance the process from a number of angles. “We have learnt how nature stores CO2 and we have realised that we can probably do better,” exclaims Junwang.

Direct photoconversion
A major roadblock in developing such technology is finding photocatalysts that can absorb as much of the solar spectrum as possible while still being efficient. As plants only use a fraction of the visible range, great potential lies in the untapped electromagnetic spectrum, so photocatalysts that respond to different regions are being investigated. Other researchers are exploring doping, nanomaterials and co-catalyst surface-loading to improve the photocatalytic response of promising materials.

However, with numerous other hurdles to climb before real-world application, Sophie expects there to be a long wait before artificial leaves are realised: “It still requires development in terms of new concepts, designs of photoelectrodes and integration of the system,” she explains. “For Cefic, it’s part of our overall long-term strategy, but more like a second- or third-generation technology that will not have impact by 2020.”

Even though tangible impact from direct photoconversion seems a long way off, Europe’s competitors are keen to advance the state of the art now, with a number of multi-million Euro projects funded in Japan, a Joint Centre for Artificial Photosynthesis set up in the US and well-funded initiatives in many other parts of the world.

As a result, Junwang believes Europe’s highly able yet currently fragmented and small community of scientists working in the area needs to be brought together: “Europe is very strong in fundamental understanding of artificial and natural photosynthesis, but countries like Japan, USA and China are investing heavily in this technology through well-funded projects. If we don’t invest more – just like has happened with graphene – other countries will heavily patent the field.”

The Cefic breakfast debate
The Cefic breakfast debate took place at the 7th European Innovation Summit in the European Parliament on 8 December. The event was hosted by Jerzy Buzek, MEP and covered the wide-ranging topic of 'Advanced Materials and breakthrough opportunities for the energy transition’.