The chemical industry stands at a critical crossroads in its journey towards sustainability. With global chemical production responsible for approximately 7% of CO₂ emissions, the sector urgently needs transformative decarbonisation strategies.
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- The demand for circular solutions and new regulatory frameworks are pushing the adoption of fossil-free chemical production, although challenges like high energy costs and technological immaturity persist.
- VTT's research is advancing electrochemical methods using carbon dioxide and bio-based sources to produce valuable monomers and high-volume chemicals such as polyols and acids, which can be economically viable even now.
- The flexibility and lower energy consumption of electrochemical processes make them cost-efficient, but their widespread adoption depends on further technological advancements, stable energy pricing, and industry-wide collaboration.
This summary is written by AI and checked by a human.
Traditionally, chemical manufacturing has heavily depended on fossil-based raw materials, creating a substantial environmental footprint. Energy-intensive processes like steam cracking have long been the backbone of chemical production, simultaneously driving industrial innovation and environmental challenges.
However, emerging technologies are promising a radical shift. Electrified processes that use renewable electricity to drive chemical transformations are opening new pathways for sustainable manufacturing. These processes allow manufacturers to incorporate non-fossil feedstocks with low carbon intensity. Electrification of chemical processes enables substantial reduction of emission intensity.
"Current production methods create significant barriers to achieving our climate goals," explains Alexander Reznichenko, research team leader at VTT.
Beyond fossil-based production
The timing for these technological innovations couldn't be more critical. Customer demand for circular and renewable solutions is growing throughout material value chains. At the same time, new regulatory frameworks and certification schemes are being developed to help these products reach the market.
However, achieving fossil-free chemical production remains challenging. The main barriers are high energy costs, limited feedstock availability, and the technological immaturity of new production methods.
"Electro-upgrading offers practical solutions," says Tom Wirtanen, senior scientist at VTT. "These technologies leverage electricity – ideally from renewable sources – to transform basic molecules directly into valuable chemicals, eliminating the need for fossil-based intermediates."
The potential impact is profound. Energy-intensive sectors such as petrochemicals and polymer production can substantially reduce their carbon emissions. Existing biorefineries and pulp mills can now leverage excess renewable energy to produce high-value chemicals while simultaneously reducing their environmental impact.
Electrified processes have the potential to reduce the carbon footprint of chemical production by up to 90%
Towards 100% CO₂-based chemicals
VTT has developed several electrochemical value chains for producing valuable monomers entirely from carbon dioxide or a combination of bio- and CO₂-based sources. These can be converted into valuable end-products like coatings, textiles, packaging, and specialty polymer applications.
“We believe at VTT, that the future impact arises from sufficient volumes, which is why we have set our focus on decarbonizing commodity chemicals,” says Reznichenko.
VTT's value chains include several high-volume chemicals such as:
- Polyols, including ethylene glycol and propylene glycol. Ethylene glycol is integral to producing PET plastics used in bottles and textiles. Propylene glycol is utilized across various industries, including food products, cosmetics, pharmaceuticals and as an antifreeze coolant.
- α-Hydroxy acids, such as glycolic and lactic acids, which are utilized in biodegradable polymers like polyglycolic acid and polylactic acid. Polylactic acid is used in packaging and consumer goods, whereas polyglycolic acid is a more emerging polymer with a lot of promise in different applications.
- Dicarboxylic acids, including succinic and adipic acids, essential in polyesters and polyamides such as nylon. Both compounds can be converted to a,w-diols that can function in polymer applications (polyesters and polyurethanes).
Interestingly, these synthesis methods are not necessarily cost-prohibitive even today.
“According to our calculations, some of the developed routes can stand on their own economically, and therefore there is no need to wait for the upcoming regulatory frameworks. Combined electro-upgrading of CO₂ with other biobased feedstocks allows for early adoption of renewable plastics with emission-based carbon content,” Wirtanen explains.
Electrochemical processes are flexible, yet efficient
One key advantage of electrified methods is their flexibility. Production rates can be adjusted quickly based on the availability and price of electricity, enhancing cost-efficiency. Electrochemical processes generally operate at lower temperatures than conventional methods, significantly decreasing energy consumption.
VTT has specialised infrastructure and expertise for electrified chemical production. With advanced testbeds and pilot-scale facilities, the research centre helps companies to cross the bridge from laboratory testing to industrial implementation.
"Our facilities help companies quickly identify the most promising electrocatalysts and processes," Wirtanen explains.
Pathways to new business models
Despite the promising potential, widespread adoption isn't imminent. Further technological advancements, stable renewable energy pricing, and industrial demonstrations are necessary.
"Industry-wide collaboration, clear policy support, and demonstration projects are crucial steps," Reznichenko says.
Once electricity becomes the primary driver of chemical manufacturing, the impact is significant. Beyond environmental benefits, these technologies could fundamentally reshape the chemical industry.
"These technologies can open paths to different business models, creating opportunities for new players and startups to innovate and develop new products," Reznichenko notes.
