INTEGRATION OF CO₂ CAPTURE AND CONVERSION IN AN INTEGRATED CO₂ RECYCLING PLANT PROTOTYPE FOR INDUSTRIAL CATALYSIS APPLICATIONS

The transition toward climate-neutral industrial systems requires the development of catalytic processes capable of integrating CO₂ capture and its subsequent valorization within efficient and scalable process schemes. In this context, this work presents a proof-of-concept of an integrated CO₂ recycling plant, aligned with the principles of industrial catalysis and process intensification, aimed at advancing CO₂ utilization technologies toward pilot and pre-commercial deployment.

The proposed system couples CO₂ capture from industrial flue gases with its catalytic electrochemical conversion into value-added chemicals, particularly formic acid and formate. The approach is positioned within energy-intensive industrial sectors such as cement, steel, and chemicals, where process emissions are particularly difficult to abate and where catalytic solutions can play a transformative role.

CO₂ capture is implemented using membrane-based separation technologies as a modular and energy-efficient alternative to conventional solvent-based processes. This step enables selective CO₂ enrichment without the need for energy-intensive regeneration, thus improving overall process integration. The captured CO₂ stream is directly fed into an electrochemical catalytic reactor, where it is reduced under continuous operation using renewable electricity and gas diffusion electrode (GDE)-based configurations.

The electrochemical CO₂ conversion stage is analyzed as a catalytic system, where catalyst performance, selectivity, and stability govern overall process efficiency. Key performance indicators include Faradaic efficiency, product distribution, energy consumption, and long-term operational stability under industrially relevant conditions.

A comprehensive techno-economic and environmental assessment, including life cycle analysis (LCA), is conducted to evaluate scalability from laboratory to pilot and demonstration scale. The integration of real flue gas streams through industrial collaboration provides additional validation of catalyst performance under realistic operating conditions and process constraints.

This work demonstrates the potential of integrating capture and catalytic conversion into a unified process framework, contributing to the development of industrially relevant CO₂ catalytic recycling technologies and supporting future deployment in hard-to-abate sectors.