95% of manufactured goods include chemicals and as the 4th largest industry in Europe, oxidative chemical conversion processes in manufacturing account for 5% of the EU’s greenhouse gas (GHG) emissions. ELOXYCHEM aims to establish a commercially relevant electrochemical oxidation process to replace existing chemical conversion methods reliant on imported materials and fossil fuels and support Europe’s green and digital by integrating renewable energy sources.

Challenges

Current chemical conversion processes heavily depend on imported materials like nitric acid and fossil fuels such as natural gas, resulting in significant environmental and economic costs. The challenge is to develop an efficient, sustainable, and versatile electrochemical process that can reduce energy consumption, operational costs, and environmental impact.

The Project

ELOXYCHEM focuses on creating a transformational electrochemical conversion platform at a pilot scale. The project consists of reactors and downstream separation processes to produce marketable end-products reliably. The goal is to achieve substantial energy consumption savings and demonstrate the versatility of the process with various feedstocks, including bio-based and biogenic sources.

Using AI strategies for optimisation, the pilot plant aims to improve electrochemical performance, enhance equipment lifetime, reduce costs, and integrate seamlessly with renewable energy sources. The project also incorporates process design from a materials, reactor/cell, and separation methods perspective, emphasising process intensification and cost reduction.

Z Prime’s Contributions

Z Prime specialises in Edge and Cloud-based AI solutions, linking field data through its iDaQ platform and IoT systems. Z Prime’s role involves translating data into actionable KPIs and providing a Decision Support System (DSS). The integration of digital technologies enables online monitoring of process parameters such as oxygen saturation, current density, substrate and product concentrations, and electrolyser fitness.

Z Prime utilises statistical approaches like the Design of Experiments methodology to optimise reaction output parameters, selectivity, and yield. By developing a Digital Twin model of the pilot plant, Z Prime provides real-time adjustments and improvements, ensuring stable operation and handling unplanned events. This approach optimises operating parameters to prevent critical states due to material fatigue.

Benefits

• Energy Efficiency: Achieves approximately 60% energy savings compared to existing processes.
• Process Optimisation: Enhances process parameters, ensuring stable and efficient operation.
• Versatility: Demonstrates the flexibility of the process with multiple feedstocks.
• Sustainability: Supports integration with renewable energy sources, promoting sustainable practices.
• Economic Benefits: Reduces reliance on imported materials and fossil fuels, lowering operational costs and environmental impact.

Conclusion

ELOXYCHEM represents a transformative approach to electrochemical oxidation processes, aligning with Europe’s green and digital transition goals. By leveraging advanced AI, machine learning, and digital twin technologies, the project optimises electrochemical processes for stability, efficiency, and sustainability. Z Prime’s contributions ensure the success of ELOXYCHEM, demonstrating its potential to revolutionise chemical industries by reducing waste, energy consumption, and reliance on harmful precursor chemicals.