Genesis-x: scaling up a CO2 valorization process for syngas and low-carbon intensity fuels

The energy transition will inevitably require a variety of solutions to meet the needs of different sectors. Among these solutions, alternative fuels will play a critical role, particularly for hard-to-electrify sectors such as aviation and maritime transport.

Secant Fuel has developed a novel Power-to-X technology that enables the conversion of CO2, water, and renewable electricity into syngas (a mixture of hydrogen and carbon monoxide). This syngas can subsequently be converted into fuels such as methanol and diesel using existing industrial processes. The fuels produced by this technology have a low carbon intensity because CO2 serves as the carbon source, and renewable electricity is used as the energy source.

Unlike other CO2 conversion technologies currently in development or available, Secant Fuel’s approach eliminates the intermediate hydrogen production stage and does not rely on electrolyzers. Instead, an electrified fixed-bed reactor is employed for the transformation, significantly reducing the costs associated with this type of technology.

Previous studies have developed the catalyst and validated the process’s techno-economic and environmental feasibility at the laboratory scale. This project focuses on scaling up Secant Fuel’s CO2-to-syngas conversion technology and integrating it with commercial methanol and diesel production processes.

A pilot unit capable of converting 40 L/min of CO2 will be constructed, enabling a maximum production capacity of 20 L/day of methanol or 1 L/day of diesel. This scale-up effort will be supported by laboratory-scale work, including catalyst shaping and the electrified reactor's heating optimization. Pilot-scale tests will help de-risk the technology and provide valuable data for techno-economic and lifecycle analyses. These insights will be critical for eventual demonstration-scale deployment by Secant Fuel and the technology's commercialization.

The city of Lac-Mégantic is also a project partner, aiming to transform its downtown into a leading-edge technological showcase in the coming years. This initiative will demonstrate the most advanced energy technologies and create a regional ecosystem where local industries can benefit from the technology to reduce greenhouse gas (GHG) emissions.

Deploying the pilot unit in Lac-Mégantic not only validates Secant Fuel’s technology at scale but also supports the city's ambition to become a hub for energy transition technologies, fostering innovation and sustainability in the region.