Novel CO2 Utilization Catalyst Recovery and Recycling

Econic's innovative catalyst technology allows 10-43wt% of high cost fossil-based feedstock to be replaced with significantly lower cost captured CO2 to produce polyols, the building blocks for polyurethane, at lower cost, with enhanced properties and more sustainably. The process to produce polyols using this patent protected catalyst technology is operated on demonstration unit scale (65L) validating that the process operates efficiently at low pressure, uniquely enabling retrofit to existing polyether polyol production assets and producing stable materials with matching or better performance characteristics. This proposal builds upon that foundational catalyst technology(TRL6); developing additional catalyst recovery, recycling and regeneration innovations which will enhance the economics of catalyst production and provide an additional circular recovery loop in the value chain.

This project validates a catalyst recycling process: capturing and regenerating spent catalyst to enable multiple uses, significantly reducing volumes of virgin material manufactured, feedstock usage, manufacturing complexity and reducing hazardous waste from the polymerisation process. This will significantly reduce catalyst manufacturing costs and further savings will be realised in our customer's waste treatment costs. By increasing sustainability of the process we reduce barriers to adoption and establish a platform for Econic and polyol producers to operate a circular economy model.

To date, we have demonstrated lab-scale (TRL2) feasibility of multiple conceptual routes for catalyst recovery and regeneration achieving 'as-new' catalytic performance. Forward development requires demonstrator (TRL6) scale processes to address key technical challenges for efficient scale-up and optimised performance. This will bring catalyst recycling TRL in line with the core process.

Econic relies on global partnerships to drive commercialisation. Suspension of a leading European customer partner's R&D activities, as a direct result of Covid-19 impact on their business, has suspended scheduled to semi-commercial scale trials to validate the Econic technology (including catalyst recovery process) at scale. Delaying parallel activities with toll manufacturers to develop catalyst recovery supply chain and validate economics. Econic must bring this work inhouse to ensure completion of the programme to validate the recovery and recycle process and meet license timelines of other pipeline customers. The work is essential to maintain the pace of commercialisation of the technology which underpins the delivery of Econic's business plan and continued investment on its growth pathway.