Beschreibung
Electrochemical conversion of carbon dioxide is increasingly discussed as a component of future Power-to-X process chains; however, its practical relevance depends strongly on the achievable process efficiency, energy demand, and overall economic performance. From a process engineering perspective, this work addresses the question of how laboratory-scale electrochemical systems can be evaluated in a consistent manner with respect to their contribution to complete process chains, with particular emphasis on techno-economic assessment (TEA).An integrated methodological framework was applied that combines laboratory experiments, metal additive manufacturing (metal 3D printing) of electrodes, and process-oriented simulations. Metal additive manufacturing was used to fabricate metallic electrodes with defined geometry, porosity, and flow accessibility, allowing reproducible investigation of electrode-related effects on electrochemical performance. Rather than focusing on detailed reactor-scale modeling, the experimentally obtained performance data were translated into simplified but physically meaningful parameters suitable for process-level evaluation.
Two electrochemical systems were considered under laboratory conditions: alkaline electrolyzers for hydrogen production and flow- and pressure-based reactors for electrochemical CO₂ reduction. For both systems, novel electrodes were developed and integrated into laboratory reactors. The systems then were characterized with respect to voltage behavior, achievable current densities, and gas evolution. These data formed the basis for subsequent process-oriented simulations, in which the electrochemical units were treated as black-box unit operations described by experimentally derived efficiencies and operating limits.
A specific experimental focus was placed on gas bubble formation at structured metal electrodes, as gas evolution was identified as a relevant factor influencing effective electrode utilization and voltage losses. Bubble formation, growth, and detachment were investigated using high-speed optical diagnostics and automated image analysis. The resulting trends were not explicitly resolved in reactor models but were instead incorporated into the TEA framework through adjusted performance parameters, such as effective current density ranges and voltage penalties.
Detailed mass and energy balances were established to quantify electricity demand, conversion efficiencies, and levelized production costs for exemplary Power-to-X pathways, with a particular focus on CO₂-based methanol synthesis. The analysis shows that electrochemical units dominate both energy consumption and operating costs within the overall process, and that variations in electrode performance directly affect economic indicators at the system level.
Overall, this study demonstrates how laboratory-scale electrochemical experiments, enabled by additively manufactured electrodes, can be systematically embedded into process-oriented TEA models. The presented approach supports a transparent and quantitative assessment of electrochemical CO₂ utilization technologies and provides a structured basis for comparing process options and identifying performance targets from a process engineering and economic perspective.
| Zeitraum | 24 Juni 2026 |
|---|---|
| Ereignistitel | e-nova: Intelligente Energie- und Klimastrategien |
| Veranstaltungstyp | Konferenz |
| Ort | Pinkafeld, ÖsterreichAuf Karte anzeigen |
| Bekanntheitsgrad | National |