UGent has successfully developed both a single-step catalytic process and a two-step chemical looping process for the conditioning of steel mill gases. The chemical looping process was evaluated in a non-adiabatic lab-scale reactor, using model BFG. The selective catalytic oxidation process was up-scaled and successfully validated on-site at Arcelor Mittal Gent with real industrial blast furnace gas.
With the aim of converting CO to high-valuable intermediates for polyol production, CEA, RWTH-CAT and Covestro worked together on providing efficient and scalable catalysts for the ring-expansion carbonylation of epoxides. Based on first application trials at Covestro, Megara and Recticel, succinic anhydride was identified as target intermediate in the CO-conversion step. The CO-derived SA was successfully applied in polyol synthesis and rigid foam production as proof of concept on lab scale. These foams showed no deviations to foams prepared from petrochemical SA. Therefore, the development and up-scaling of polyol recipes was conducted using commercial intermediates. Furthermore, the feasibility of gas mixtures was demonstrated for the new CO-conversion and the established CO2-technology.
The most promising synthetic recipes for polyol production were optimized on kg-scale and sampled to the project partners Recticel and Megara for initial lab trials. According to their feedback certain polyol recipes were optimised and scaled to pilot-plant scale (450 kg).
Recticel performed a series of trials in which reference polyol was partially replaced with the different Carbon4PUR polyols. Up to 70% of the standard polyol can be replaced by Carbon4PUR polyol when higher surfactant levels are applied to make insulation boards with technical specifications comparable to the market reference (TRL 6).
Megara performed synthesis and characterisation of several formulations of waterborne polyurethane dispersions (PUDs) and optimised their properties to set the basis for up-scaling at semi-industrial scale and application testing. Overall, the properties of the PUDs obtained by using the Carbon4PUR polyol were fulfilling the requirements of wood coatings (TRL 6).
RWTH-AVT combined all technologies to a holistic process concept as foundation for the accompanying environmental, economic, and social assessments. Several scenarios were assessed. Moreover, research focussed on the acceptance and perception of CCU has been done by the RWTH-COMM to help understanding consumer needs and potential market barriers.
The Carbon4PUR website www.carbon4PUR.eu as the main information source for the public contains all public deliverables and scientific publications as well as other outcomes like the Carbon4PUR Mapping Tool, project videos and other communication materials including the public stakeholder events.
With respect to exploitation actions, a stakeholder analysis and a market analysis has been performed. Detailed implemented or foreseen exploitation actions include the application for 16 patents, 2 spin-off potentials, and the publication of six master and seven PhD theses. Finally, obtained knowledge shall be exploited in follow-up projects.
