Advanced catalysts and improved processes to convert CO₂ into e-fuels

The project has focused on two key thermocatalytic routes:

• Reverse Water Gas Shift (RWGS): conversion of _CO2 into synthesis gas, which is subsequently transformed into e-fuels through the Fischer-Tropsch (FT) process.

• Hydrogenation from CO₂ to methanol: a strategic pathway to produce e-methanol, used as marine fuel or as a precursor to other e-fuels.

Main actions

A pilot plant has been designed and built at our Innovation Center in Alcalá de Henares for CO₂ conversion tests under representative conditions, and an advanced unit has been incorporated to study the complete RWGS-FT process, aimed at the synthesis of synthetic sustainable aviation fuel (e-SAF).

The partnerships with ICP-CSIC and the University of Seville have been essential for developing efficient catalysts for the RWGS process, achieving high conversions and CO selectivity (>90%) and stability under demanding conditions. As a novel aspect, advanced formulations have been created to operate at lower temperatures (≈500 °C), using non-critical metals and promoters that enhance selectivity and reduce energy consumption.

In the field of the Fischer-Tropsch process, tests have been conducted to transform the synthesis gas obtained in the RWGS into liquid hydrocarbons, optimizing the operating conditions for the production of e-SAF. This study has allowed to validate the operability of the process and establish critical parameters for its scalability.

Finally, in the CO₂ hydrogenation route to methanol, state-of-the-art catalysts provided by industrial technologists have been evaluated under realistic operating conditions. In addition, strategies to intensify the process have been addressed, such as the use of adsorbents to eliminate the water generated during the reaction, resulting in improvements in conversion and selectivity.