Scaling-up electrochemical technologies for renewable ethylene production

A much-needed circular carbon technology

Ethylene, the most produced molecule in the chemical industry (~180 million tonnes per year), is currently manufactured through energy-intensive processes based on fossil feedstocks. Developing alternative routes, such as Carbon Capture and Utilisation (CCU) technologies, is essential to ensure access to low-carbon future materials and fuels.

Direct ethylene electrosynthesis (low-temperature CO₂ electrolysis) has shown promise at laboratory scale (TRL3), with potential to compete with other “green” ethylene production methods, especially if combined with large-scale offshore wind energy deployment. The next step is to further develop and scale-up the technology towards a first industrial pilot (TRL6).

Strategic collaborations with academic and industrial partners

The successful scale-up of electrochemical CO₂-to-ethylene technology requires coordinated efforts across several aspects of technology development.

TNO has initiated a multi-year multi-million euro program collaborating with key international academic partners, including CEA (France), TU Delft (The Netherlands), and TU Valencia (Spain), to integrate knowledge at all levels and accelerate the development of this technology.

PhD researchers from these universities will work alongside TNO scientists and engineers, while the recently awarded RVO-MOOI project RESET-CO₂ involves SME’s and industrial partners such as VSParticle, Brusche Process Technology, e-ethylene, and Johnson Matthey.

Impact

This initiative aims to demonstrate before 2030 the feasibility of large-scale electrochemical production of olefins, a crucial component in plastics, coatings, and synthetic materials. When successful, this will enable the chemical industry to start implementing a first-of-a-kind industrial scale plant before 2040.

By advancing these electrochemical conversion technologies, TNO is helping the industry de-risk the scaling up and accelerating commercialisaiton towards an electrified chemical sector. These efforts contribute to decarbonisation and circular economy goals, offering a pathway to replace fossil-based raw materials with sustainable alternatives.

'This project is a very strong example of our commitment to develop low-carbon, circular solutions for the chemical sector,' said Richard Braal, Division Director Industry within TNO’s Energy and Materials Transition Unit.

Senior Scientist Michele Tedesco adds, 'By advancing electrochemical conversion technologies, we are making concrete steps towards understanding the technology hurdles & steps that need to be taken to realise the first industrial pilot of CO2-based ethylene.'