Commercial Demonstration Plant to Manufacture Synthetic Hydrocarbon Fuels from Renewable Power ("eFuels"): Phase-1A-Extended (Technology and Design - Catalyst Optimisation)

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Innovate UK
Innovate UK

£126,376

Jan. 1, 2021

March 30, 2021

ZERO Petroleum will develop technology and production plant to synthesise hydrocarbon fuels using water and carbon-dioxide (as the raw ingredients) and renewable electricity (for the energy). These synthetic fuels are called "electrofuels" or "eFuels".

The focus for the first plant - a 1MW Commercial Demonstration Plant, converting approximately 3000kg of carbon-dioxide to 1000kg of hydrocarbons per day - will be on drop-in replacements for fossil-sourced regular gasoline and LPG products (butane and propane). In later phases the technology can and will be diversified to other hydrocarbon fuels (such as diesel and jet fuel) and other petroleum-based non-fuel products (plastics and chemicals).

The ZERO Petroleum Commercial Demonstration Plant will be

* the first synthetic hydrocarbon fuel plant and commercial supply in the UK, and
* the first gasoline- and LPG-priority synthesis plant and commercial supply globally.

As part of the technology research phase of the project, supported by Innovate UK funding, ZERO Petroleum will optimise the catalyst technology for the synthesis process (converting carbon-dioxide and hydrogen to the target hydrocarbons) so as to maximise yield. Although the base technology (called "Fischer Tropsch") is well-established and proven commercially, the technology to prioritise gasoline and LPG production is unique and highly innovative. The output from this research stage will enable the best possible efficiency and consequent profitability of the final Commercial Demonstration Plant.

If synthesised using renewable electricity (for example, from wind or solar PV), eFuels are inherently carbon-neutral and compatible with a circular economy. Although the eFuel itself emits carbon-dioxide upon combustion the synthesis process is drawing the same quantity of carbon-dioxide from existing carbon-dioxide emitters (such as a fermentation or cement manufacturing process) or, eventually, from the atmosphere by a process in development called Direct Air Capture. The consumer of the eFuel (vehicle, heating, etc.) is hence operating in a carbon-neutral and fully sustainable manner: material is neither dug out of the ground (fossil fuels) nor buried in the ground to compensate (carbon sequestration).

eFuels are in effect renewable fuels which directly and seamlessly displace fossil fuels where no other options are possible or preferred. The innovative technology and process engineering associated with the ZERO Petroleum programme will therefore play a central and vital role, alongside renewable electricity and hydrogen, in the decarbonisation of global energy. Whilst the COVID-19 epidemic has temporarily reduced the rate of carbon-dioxide emissions and given a perception of "good news", the reverse is actually the case. COVID-19 has extended the carbon budget for 1.5/2.0°C of global warming by 1-2 months at best; meanwhile the COVID-19 lockdown has much further delayed the development and construction of decarbonised energy systems. The global warming crisis is consequently more acute. Innovate UK's funding of ZERO Petroleum's eFuel technology programme within the Temporary Framework is therefore an important component of the UK's response to COVID-19 as well as the Climate Emergency.