Presentation of the NEFI project directCCE at the NEFI Technology Talk “CO₂ as a Resource – Technologies and Opportunities”

CO₂ is no longer merely regarded as a waste product – it is increasingly recognised as a valuable resource. In particular, the steel, chemical, and cement industries are exploring new possibilities through so-called CCUS technologies (Carbon Capture, Utilisation & Storage) to reduce emissions and utilise CO₂ as a feedstock.

How CO₂ can be used as a raw material in future industrial processes was the central topic of the NEFI Technology Talk “CO₂ as a Resource – Technologies and Opportunities”, held on October 16^th, 2025, at the Technical University of Leoben. Researchers, industry representatives, and funding institutions discussed current developments, challenges, and future perspectives. The Climate and Energy Fund also presented new funding programmes and provided valuable impulses for the development of innovative projects.

The NEFI Project directCCE

A highlight of the event was the presentation of the NEFI project directCCE, which pursues a novel approach to CO₂ utilisation. In this process, CO₂-laden solvent is directly converted into synthesis gas within an electrolysis cell — a mixture of carbon monoxide (CO) and hydrogen (H₂) that serves as a basis for chemical products such as methanol or synthetic fuels.

In contrast to conventional methods, directCCE eliminates the thermal step of CO₂ separation. This makes the process more compact, energy-efficient, and potentially more cost-effective.

Research Findings from TU Wien

The team of the Technical University of Vienna presented current results on the development of the electrochemical cell, the test facility, and ongoing scale-up activities. Particular emphasis was placed on the ability to precisely control the ratio of CO to H₂ in the synthesis gas — for example, by adjusting the cell design or current density. Model calculations indicate that pH values between 8.5 and 10 provide particularly favourable conditions for coupling absorption and electrolysis.

By recirculating the solvent, the process can be flexibly adapted to different substance systems without exceeding emission limits. Cells with active areas of 16 cm² and 100 cm² are currently being tested, while upscaling to 200 cm² cells and a 600 cm² stack is in preparation. Initial 16-hour endurance tests already demonstrate high stability. In a planned pilot operation at Wien Energie, the system will be tested under real conditions using flue gas from a waste incineration plant.

Accompanying Research and System Integration

In parallel, the University of Innsbruck is investigating electrochemical processes on a laboratory scale (5 cm² cells). The aim is to gain a deeper understanding of electrode and layer behaviour and to assess the potential for increasing conversion efficiency and selectivity.

At Montanuniversität Leoben, various integration pathways for industrial applications are being simulated. Three process routes are being analysed: two involving thermal CO₂ separation and one based on direct electrolysis. Initial comparisons show that the directCCE approach achieves the highest CO₂ conversion rate, while high-temperature electrolysis demonstrates particularly high energy efficiency.

Future studies will focus on how directCCE can be integrated into existing industrial processes. The CO₂ concentration in exhaust streams will play a decisive role, as it significantly affects the efficiency of different CCU pathways.

Conclusion

The NEFI Technology Talk 2025 highlighted the rapid progress being made in CO₂ utilisation and valorisation research. With directCCE, an innovative approach was presented that holds the potential to make industrial processes more sustainable — contributing substantially to the transition towards a CO₂-neutral industry.

Further information on the project is available here: directCCE – Direct Carbon Capture and Electrolysis.