Advanced Energy Materials, LLC SBIR Phase I Award, June 2022

Polyethylene furoate (PEF) is one of the bioplastics for making water bottles, beverage bottles, fibers, and films. PEF is a 100 % bio-based polymer derived from plants having the potential to replace the plastic industry’s giant polyethylene terephthalate (PET), which is a durable material derived from conventional resources. Commercially, the PEF has been produced in two steps: (1) 2,5-Furan dicarboxylic acid (FDCA) from 5-HMF oxidation (ii) polycondensation of FDCA and ethylene glycol. The produced PEF from 5-HMF has a negative impact on the polyester properties (coloration, thermal instability, decreased electrical performance, and potential environmental and health problems) owing to sugar impurities in FDCA and the residual amount of metals in the final product PEF. ADEM proposes an innovative two-step DBD plasma-assisted process for PEF synthesis using CO2. In the 1st step, ADEM proposes an unique plasma-catalytic approach for CO2 carboxylation in a gas-solid reaction scheme to produce FDCA under atmospheric pressure. ADEM proposes a similar approach for the second step of polycondensation reaction between FDCA and ethylene glycol. The proposed process can provide potential benefits: reduction in energy consumption, faster reaction time, solvents, and no expensive catalysts. No external heat supply is required to activate reactants as the energy supply from plasma. Advanced Energy Materials LLC (ADEM) has been developing several nanowire-based catalysts which exhibit higher performance and durability due to non-sintering and high dispersions (or compositions) of catalytically active sites. Phase I of the proposed project involves four major components: (1) demonstrate the FDCA synthesis using CO2 and 2-furoate using the proposed process at 10-30 Lpm/kW of throughput with the assistance of nanowire support, optimize the process conditions to improve the conversion and selectivity; (2) demonstrate the PEF synthesis from polycondensation of FDCA and ethylene glycol under similar plasma approach and find out the feasibility of recycling of nanowire supports. (3) Techno-economic and life cycle analysis for cost-effective production of PEF and perform technical validation. (4) Program management and reporting the data. Commercial Applications and Other Benefits: The rapid growth of the plastics industry demands greener plastics that are developed from renewable biomass. The utilization of CO2 as a feedstock ultimately decreases CO2 emissions, a major anthropogenic greenhouse gas (GHG). The development of CO2 utilization technologies is attracted considerable attention in recent years due to new government policies. The global market for PEF is rapidly growing at a CAGR of 7.12%. PEF production from CO2 and 2-furoate using DBD plasma catalysis technology can be promising for CO2 capture and conversion in carbon-intensive industrial processes, such as cement plants, steel mills, and hydrogen plants.