Low rate production pilot line for CO2 electroreduction Membrane Electrode Assembly fabrication
Design, build and validate a Low Rate Initial Production pilot line for the manufacture of innovative membrane electrode assemblies (MEAs) that convert carbon dioxide emissions into valuable carbon compounds using renewable electricity as input.
Twelve Benefits Corporation
Recipient
Berkeley, CA
Recipient Location
7th
Senate District
14th
Assembly District
$3,000,000
Amount Spent
Active
Project Status
Project Update
In 2022, facilities expansion have been completed and preparation for the LRIP pilot line are ongoing. The prototype fabrication unit has been validated, demonstrating equal performance to baseline fabrication capabilities at significantly improved throughputs. Process modifications for LRIP operation are under investigation. The specifications for the LRIP pilot line have been fully defined; this system has been designed and is currently being built. New hires for validating and operating the pilot line have been onboarded.
In 2023, the following milestones were achieved:
(1) Built an LRIP pilot line capable of producing ~3-4x the current capacity of producing electrode active area;
(2) Validated manufacturability of the new LRIP line;
(3) Built a manufacturing workforce with the identified skillsets necessary to operate the new pilot line; and
(4) Fine-tuned the pilot line operating procedures for high throughput and good process quality control.
In 2024, work focused on optimization of quality management, final validation of the LRIP pilot line, and final deliverables. The following milestones were achieved:
(1) Process improvements were implemented to improve throughput of the LRIP pilot line, allowing for the fabrication of 34,000 cm2 of MEA area per day.
(2) Successfully transferred and validated the deposition process of our previous fabrication tools on the LRIP pilot line, achieving ± 2-5% variation relative to target specifications over 600 samples.
(3) Assembled a workforce of 20 individuals to operate and manage the new pilot line, as well as characterize MEAs in- and off-line.
(4) Iterated on operation and process parameters, achieving over 90% MEA yield and enabling the fabrication of 34,000 cm2 of MEA area per day.
The Issue
Today's industrial processes are dependent on fossil fuels for raw materials and process energy inputs and emit CO2. Although strides are being made for less carbon intensive processes and electrification, today's infrastructure will continue to need carbon-based compounds and emit CO2 as waste.
Project Innovation
The purpose of this project is to design, build, and validate a Low Rate Initial Production (LRIP) pilot line for the manufacture of innovative membrane electrode assemblies (MEAs) that use carbon dioxide emissions as feedstock to produce valuable carbon compounds with the input of renewable electricity. The MEAs provide a technological pathway to electrify and decarbonize the production of chemical and industrial products, and improve the marginal value of new solar PV generation by enabling on-demand production of these materials during times of potential overgeneration.
Project Goals
Project Benefits
This project will lead to technological advancement and breakthroughs to overcome barriers to the achievement of the State of California's statutory energy goals by scaling up production of the Recipient's innovative membrane electrode assemblies (MEAs) that use carbon dioxide emissions as feedstock to produce valuable carbon compounds with the input of renewable electricity. The MEAs provide a technological pathway to electrify and decarbonize the production of chemical and industrial products, and improve the marginal value of new solar PV generation by enabling on-demand production of these materials during times of potential overgeneration.
Affordability
A high efficiency CO2 electrolyzer could take excess electricity during times of overgeneration and convert it into valuable products and fuels (e.g., jet fuel, clean diesel).
Environmental Sustainability
The Recipient’s technology could also increase public safety by improving air quality. CO2-derived liquid fuels, such as jet fuel, would have significantly lower sulfur content and burn cleaner than petroleum-derived diesel.
Reliability
CO2 electrolysis can load follow, ramping up or down in seconds, and provide greater stability in the grid. The CO2 electrolysis systems would be a reliable offtake for surplus electricity.
Safety
CO2 electrolysis would increase safety by significantly reducing CO2 emissions, thereby reducing the impact of climate change, which translates into lower risks of fire and flooding, among others.
Key Project Members
Danny Hellebusch
Sydney Chiu
Match Partners
United States Department of Energy
Opus 12 Incorporated
