Advancing Carbon Conversion through Innovative DMC Processing
Funded through the Grand Challenge: Innovative Carbon Uses Round 1 in 2014, the E3Tec Service, LLC project set out to develop a process for converting captured CO2 into di-methyl carbonate (DMC)—a value-added chemical with broad industrial applications. In collaboration with Michigan State University, E3Tec created an energy-efficient process that combines heat-integrated reactive distillation (HIRD) with side reactors. These reactors use either PerVaporation (PerVap) membranes or side reboilers to separate byproducts and excess reactants. The resulting CO2-based DMC offers a low-carbon-footprint alternative with strong potential for emissions abatement in Alberta.
The project progressed from proof-of-concept to integrated system testing, validating two production pathways: one based on urea and the other on ethylene oxide. ASPEN Plus® process models were developed and validated using kinetic and pilot-scale data, enabling commercial-scale design. The team also completed preliminary designs for a pilot plant in Alberta and identified integration opportunities with local methanol and ethylene oxide producers. With robust IP protection and promising techno-economic performance, E3Tec positioned themselves to demonstrate the technology at pilot scale and pursue commercialization through licensing or strategic partnerships.
Demonstrating Dual Pathways for Efficient DMC Production
The project showcased the flexibility of the DMC process through two distinct chemical routes. The urea-based pathway demonstrated strong CO2 utilization potential, while the ethylene oxide route enabled co-production of mono-ethylene glycol (MEG), a high-value commodity chemical.
Both pathways were modelled using ASPEN Plus® and validated with pilot-scale data, confirming their energy efficiency and lower carbon footprint compared to conventional SynGas-based DMC production. E3Tec also explored integration opportunities with Alberta-based methanol and ethylene oxide producers to further reduce lifecycle emissions and enhance economic viability.
What’s next?
As of 2021, E3Tec plans to advance the technology by demonstrating an integrated pilot system in Alberta. The team will refine the process design, complete pilot-scale validation, and select the most promising pathway—urea-based or ethylene oxide-based—for commercial deployment. To support this, E3Tec is pursuing partnerships with methanol producers such as Methanex and Enerkem, and ethylene oxide producers like Shell Chemicals, to integrate the DMC process with existing infrastructure. With validated models, strong IP, and growing market demand for DMC in polycarbonates, solvents, batteries, and fuel additives, E3Tec is well-positioned to commercialize its CO2-to-DMC technology and contribute meaningfully to Alberta’s emissions reduction goals.