Revolutionary method for synthesizing chemicals, minus the conventional, polluting industrial plants
In the heart of Richland, Washington, a new player in the global chemicals industry is making waves. OCOchem, a startup led by CEO Todd Brix, has embarked on a mission to revolutionise chemical production, aiming to replace large fossil fuel-powered plants with numerous small, electric machines.
OCOchem's innovative approach to formic acid production is chemically simple yet groundbreaking. The process involves CO2 being combined with two hydrogen atoms, resulting in formic acid. This method, unlike traditional methods, does not rely on methanol and carbon monoxide from fossil fuels.
The company's pilot plant, now operational, employs water and carbon dioxide, using electrically operated 1.5-meter electrolyte modules. OCOchem's vision is to mass-produce these chemical plants, lowering costs over time, much like the solar industry's approach.
Scaling out OCOchem's technology involves manufacturing more modules, enabling rapid increases in formate production. The company's $5 million project can currently produce up to 60 tons of formic acid per year, a relatively small amount compared to the global production of approximately 1 million tons per year. However, OCOchem is preparing to scale up manufacturing to meet over $300 million in prepurchase contracts.
Being able to cost-effectively produce industrial chemicals in small amounts is one of the selling points of OCOchem's technology. The power of economies of scale from mass production allows OCOchem to make many small chemical plants and stack them together for increased production.
Researchers have been attempting to use electrolysis to produce formate for decades, but scaling up cells to commercially viable volumes has been a challenge. OCOchem's patented technologies have enabled them to scale up their reactor size by a factor of 1,500, handling the required current density.
OCOchem manufactures key components for its cells and works with a contract manufacturer to assemble them. The startup has raised $5 million in 2023 and secured grants and early-stage support from Halliburton Labs for its technology development.
The global chemicals industry, relying heavily on fossil fuels, stands to benefit significantly from OCOchem's innovative approach. The company's electrolytic cells operate at ambient temperatures and pressures, emitting only formic acid. This process, likened to 'artificial photosynthesis,' uses water, carbon dioxide, and electricity.
Formates produced by OCOchem are used in various applications such as deicing airplanes and preserving animal feed. As OCOchem continues to scale up its operations, the potential for a greener, more sustainable chemicals industry becomes increasingly promising.
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