This talk will discuss ongoing efforts within the National Energy Technology Laboratory (NETL) to develop catalyst materials and electrified processes to produce decarbonized chemicals. Specific topics include microwave-assisted methane mixed reforming for the production of carbon negative methanol and the electrochemical conversion of CO₂ into liquid chemicals. Both electrified pathways utilize CO₂ as a reactant and substantially reduce carbon emissions compared with current, state-of-the-art processes. Methanol is a widely used industrial chemical, and CO₂ derived methanol can be upgraded into sustainable transportation fuels. Microwave-assisted catalysis is an extremely energy efficient approach to promoting thermal reactions, but materials development requires unique design considerations to create materials that can absorb microwaves, generate heat, and sustain catalytically active surface sites under a range of conditions. Our work has produced a class of catalysts that can promote the reforming of CO₂ and methane into syngas ratios suitable for methanol synthesis. TEA and LCA suggest favorable economics and a substantial reduction in CO₂ emissions compared with traditional fossil-based methanol production. Secondly, NETL's materials development activities have also produced new electrochemical catalysts with some of the highest activities currently reported in the literature for formic acid production, which is an emerging liquid hydrogen carrier. Precise control over the material’s surface structure and composition drastically improved catalyst efficiency, and we have successfully demonstrated industrially-relevant current densities in realistic, full-cell "electrolyzer" devices. Both of these electrified processes have the greatest decarbonization potential when powered by non-fossil electricity (wind, solar, etc.), but the cost of renewable electrons remains a major cost driver. Our findings suggest careful catalyst design is a key aspect for achieving economically viable chemical production by improving system energy efficiency and lowering total electrify requirements.

Dr. Christopher Marin

Battelle

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