Transforming Emissions into Chemicals Through Chemical Engineering
Funded through Round 1 of the Grand Challenge: Innovative Carbon Uses in 2014, Enerkem Inc. set out to identify industrial CO2 sources and convert them into marketable chemicals—such as acrylic acid—that sequester CO2 directly within their molecular structure. A techno-economic analysis confirmed the potential of dry methane reforming (DMR) to capture CO2 and produce syngas, which was then evaluated for direct conversion into dimethyl ether (DME) through a single-step process.
This reforming approach offers an alternative to traditional carbon capture by turning emissions into raw materials—carbon monoxide and hydrogen—for chemical synthesis. Over the course of the project, Enerkem developed several catalytic processes that use syngas to maximize carbon capture. These include a stable, regenerable catalyst for iodide-free DME carbonylation to produce methyl acetate, improving both economic and environmental performance. In addition, Enerkem developed or repurposed two other catalyst formulations that lay the foundation for green chemistry-based CO2 utilization: hydrolysis of methyl acetate to acetic acid, and aldol condensation of formaldehyde and acetic acid to produce acrylic acid.
Demonstrating CO2 Conversion Through Catalytic Processing
Building on these innovations, Enerkem successfully demonstrated the feasibility of converting CO2 into high-value chemicals—methyl acetate, acetic acid and acrylic acid—using novel, iodide-free catalytic pathways. These processes reduce reliance on corrosive and costly co-catalysts while improving environmental outcomes.
The project validated the use of DMR to generate syngas, which was then used in a series of carbonylation and condensation reactions. Bench-scale testing confirmed that Enerkem’s proprietary catalysts maintained high selectivity and conversion rates, with promising results for acrylic acid production via aldol condensation of formaldehyde and acetic acid. The integrated process design—leveraging syngas from municipal solid waste and industrial CO2—demonstrated strong greenhouse gas (GHG) reduction potential and laid the groundwork for scalable, distributed chemical manufacturing in Alberta.
What’s next?
As of 2019, Enerkem is preparing to scale its CO2-to-chemical platform from bench-scale validation to pilot-scale demonstration. The next phase will focus on optimizing catalyst regeneration, refining separation systems for intermediates like methyl acetate and acetic acid and scaling up the integrated process.
The company plans to deploy this bolt-on technology at existing Enerkem bio-refineries, particularly in Alberta, where municipal waste and industrial CO2 streams are abundant. With the potential to reduce emissions by up to one megatonne of CO2 using four to five commercial modules, Enerkem is also exploring strategic partnerships and investment opportunities to commercialize acrylic acid production from waste-derived methanol and syngas.