Carbon Nanoplatelet (CNP) Production from Exhaust CO2 Emissions

Lead Proponent: Carbon Upcycling Technologies Inc. (CUT)
Location: Calgary, AB
EIP Contribution: $ 3,339,050 
Project Total: $ 7,858,506
Strategic Area: Carbon Capture, Use and Storage

Project Objectives:

Phase I of this project saw the construction of a pilot demonstration facility to capture CO₂ emissions and combine them with low grade solid feedstock (e.g. derived from fly ash from coal power plants) to create exfoliated carbon nanoplatelets (CNPs). CNPs can be added to concrete mixes, which results in a concrete that has enhanced compressive strength. The demonstration plant has a production target of 500kg of CNPs/month.

The pilot plant will also provide samples to initiate commercial sales of the product into existing concrete product lines, while helping to create successful market entry and direct sequestration and valorization of CO₂ emissions in Alberta.

Phase II of the project will include testing at the Alberta Carbon Conversion Test Centre (ACCTC), to progress to a full day of operations. All sub-segments of the integrated Project system will be tested and undergo safety testing. Subsequently, the 3-month operation of the integrated Project will be achieved with over 80% operational uptime. Operation and testing reports confirming 2 tonne per day maximum capacity of production will be proven more than 5 times, as will be CO₂ capture of over 200 kilograms per day.

Expected Results:

In Phase II Carbon Upcycling intends to produce 10 tpm of graphitic nanoplatelets (GNPs) and enhanced fly ash (EFA) to create additives for the construction, polymers, lithium ion battery additives for the energy storage and renewable energy industries using its proprietary, patent-pending mechano-chemical exfoliation process.The testing will result in at least 1 commercial trial completed for CUT EFA in commercial concrete Project.

The platform technology that will be utilized in this reactor is a novel approach to CO₂ valorization and the scale up of this technology will advance the Canadian clean tech industry by exemplifying the offering of CO₂ for economic growth.  This will also improve competitiveness and aid in finding more efficient and valuable uses for CO₂.

By upcycling fly ash, the technology can also facilitate the development of progressive regulations around higher cement displacement of cement with fly ash, thereby reducing the carbon footprint of new builds and retrofits.

Partners:

COSIA Carbon X-Prize
Burnco Ready Mix Concrete
Lafarge-Holcim
Positec