Converting Carbon into Chemicals with Catalyst Innovation
Funded through the Grand Challenge: Innovative Carbon Uses Round 1, the RTI International project aimed to develop a novel catalyst system that uses captured carbon dioxide (CO2) to produce ethylene oxide (EtO)—a high-value chemical used in the production of plastics, solvents and antifreeze. The project focused on designing and testing a family of mixed-metal oxide catalysts capable of abstracting oxygen from CO2 and transferring it to ethylene, forming EtO. This approach offers a potential alternative to conventional ethylene oxidation processes, which rely on pure oxygen and generate significant greenhouse gas emissions. RTI’s process also produces carbon monoxide (CO) as a valuable by-product, further enhancing its relevance to Alberta’s petrochemical sector.
Over the course of the project, RTI developed and tested more than two dozen catalyst formulations using both transport and cofeed reactor modes. Bench-scale testing demonstrated EtO yields of up to 8.5 per cent, which is comparable to conventional processes, while also achieving significant CO2 utilization. Process modelling and techno-economic analysis showed that the cofeed mode offered the most cost-effective path forward, with the potential to reduce more than four tonnes of CO2 equivalent for every tonne of EtO produced. These results support the viability of RTI’s catalyst technology as a low-emissions alternative for EtO production in Alberta and beyond.
Scaling Toward Commercial Readiness
Building on its catalyst development success, RTI International conducted detailed process modelling and techno-economic analysis to assess the feasibility of scaling the technology for industrial use. The team evaluated two reactor configurations—transport and cofeed modes—and determined that the cofeed mode offered the best balance of economic performance and greenhouse gas reduction. With EtO yields comparable to conventional processes and the potential to avoid more than four tonnes of CO2 equivalent per tonne of EtO produced, the technology presents a compelling case for further development. RTI also produced a preliminary design package for a pilot-scale system and identified Alberta as a promising location for future deployment, given its strong ethylene production base and carbon management infrastructure.
What’s next?
Since project completion, RTI International has not advanced its ethylene oxide catalyst technology toward commercialization in Alberta. While the final report outlined a roadmap for pilot-scale testing and further catalyst optimization, the project did not secure the local partnerships or investment needed to move forward in the province. However, RTI has remained active in carbon utilization and clean chemical production. The organization has continued to refine its catalyst systems and process models and has expanded its focus to other high-impact applications. While the technology did not progress in Alberta, RTI continues to be active in this area and was awarded $10 million in U.S. Department of Energy ARPA-E funding in 2025 to pursue ammonia production.