SBIR Phase IIB:CO2 to Chemicals: A Hybrid Process for Bioproduct Synthesis from CO¬2

The chemical industry is seeking new domestic feedstocks that are independent of imported oil. Waste CO2 is an abundant and low-cost domestic source of carbon for making chemicals but there is a need for new technologies to cost-effectively capture and convert CO2 into useful materials. The objective of this project will be to develop an economically viable process that converts waste CO2 from sources such as industrial fermentation or cement production into valuable bio-products using excess renewable electricity as an input. This project will integrate technology for efficient electrochemical conversion of CO2 into CO with gas fermentation technology to convert CO into fuels and chemicals. A lab-scale system with a CO2 electrolyzer integrated with a gas fermentation bioreactor was successfully demonstrated. The electrolyzer was scaled to the 600 cm2 size and stacks of cells each of which had an active area of 600 cm² was built. The Phase IIB work will modify the electrolyzer stack so it can operate with CO2 generated from a batch fermenter, the electrolyzer will be integrated with a 1000 L batch ethanol at NREL, and the device tested. Upon success, this project will provide a scalable pathway to new production of key chemical intermediates from waste CO2, creating new jobs and revenues for U.S. manufacturing by monetizing a high volume, low value waste and offering new domestic sources of supply for the U.S. chemicals industry. Isopropanol is an initial target molecule that serves a $2.75B market, primarily for use as a solvent. The chemicals will be co-produced with ethanol, a feedstock for making sustainable alternative jet fuel (SAJF) using an Alcohol-to-Jet process. Co-production of chemicals will enable the cost of SAJF to be competitive with conventional jet fuel.