Scale-Cat

Scalable and Sustainable Catalysts as Efficient Key Technology for the Production of Green Methanol

(deutsche Version)

This project will investigate for the first time the use of high-purity, laser-generated catalytic materials in combination with bio-based, meso- and macroporous carbon bodies as support materials to develop an innovative catalyst for the efficient synthesis of methanol by the hydrogenation of CO₂.
Reducing CO₂ emissions is a key part of combating climate change. One way is to bind CO₂ in sustainable products, e.g. by catalytic synthesis of methanol. As a base chemical, methanol is an important starting point for many chemical products. Special catalysts are needed for this purpose, which should have high conversion rates and a long lifetime. Commercial catalysts can only meet these requirements to a limited extent, since the catalytically active nanoparticles agglomerate or are discharged over time under reaction conditions. The production of these commercial catalysts (support materials Al₂O₃, ZrO₂) is resource and energy intensive and no sustainability aspects are considered.
In the present project, nano-material colloids will be produced in water by means of laser ablation, which will largely eliminate the need for fossil-based, toxic chemicals. Metallic raw materials from recycling processes are to be used, with the focus on Cu, Ni, Zn and Zr and their combinations. Precious metals and critical elements are to be avoided. Porous bio-based carbon bodies with optimized pore structure and surface will be developed as carrier material, which will then be loaded or impregnated with the nanoparticles. By adjusting the pore structure to the particle size, subsequent agglomeration of the nanoparticles and their discharge can be prevented/strongly reduced, thus significantly increasing the performance and lifetime of the catalyst.
By converting CO₂ to methanol, the climate-impacting greenhouse gas can be utilized (CCU Carbon Capture and Utilization) and thus the Sustainable Development Goals (SDGs), especially combating climate change (SDG13) and sustainable consumption and production methods (SDG12) can be advanced.
The targeted immobilization and fine distribution of the nanoparticles on the bio-based porous carbon support material reduces the proportion of metals required (e.g. Cu) in the production of the new catalysts. The formability of the support material creates the possibility of a flexible reactor design, allowing individual process parameters to be further optimized (e.g. efficient reactor heating).
At the end of their life cycle, the new catalyst materials can be easily reprocessed in terms of circular economy (thermal decomposition) and thus the metals can be recovered. In this way, a closed raw material cycle with high sustainability is realized.
The life cycle assessment is conducted according to ISO 14044 and includes the analysis of the production system to be examined (synthesis of nanomaterials, production of carrier materials, etc.), it includes the assessment of potential positive and negative environmental impacts (CO₂ emissions etc.).
The aspects of efficient use of resources and raw materials as well as efficient production technologies are playing an increasingly important role for society. This project is intended to take a forward-looking step for sustainable production technologies.