The SPAT-eCat project represents a transformative step in the development of sustainable chemical processes, focusing on the production of bio-based adipic acid through electrified catalysis. Adipic acid, a key component in the polymer industry, is currently produced primarily from fossil-based resources via processes that release harmful byproducts, such as nitrogen oxides (NOx). Despite several attempts to commercialize bio-based adipic acid production, these efforts were discontinued due to economic challenges. The SPAT-eCat project addresses this gap by introducing a novel approach to adipic acid synthesis, utilizing electromagnetic heating of magnetic catalysts to achieve highly efficient and selective reactions while reducing environmental impact and process costs. The innovative use of electromagnetic heating enables localized heating of the catalyst surface, minimizing heat loss to the surrounding liquid phase. This approach enhances catalytic stability by reducing the leaching of active metals, such as rhenium, into the reaction medium, which significantly extends catalyst lifetime. Initially, the process will be optimized in batch reactors to achieve maximum catalytic efficiency. Subsequently, it will be scaled up to continuous flow systems, which will intensify the process and ensure sufficient quantities of bio-based adipic acid or its esters. Advanced separation and purification techniques will be developed to achieve product purities exceeding 95%, meeting the stringent requirements for industrial use. In addition to optimizing the production of adipic acid, the project expands its scope by integrating the oxidation of sugars into aldaric acids, enabling the use of renewable resources like lignocellulosic biomass. This step aligns with the principles of the circular economy, fostering the sustainable valorization of waste streams. The oxidation of sugars will involve the design of new catalysts, such as doped zeolites or silicates, tailored for efficient conversion, followed by thorough characterization and catalytic testing. A critical component of the project is the socio-techno-economic assessment, which will evaluate the feasibility and competitiveness of the proposed bio-based process compared to traditional fossil-based methods. Using process simulation tools like Aspen Plus, mass and energy balances will be calculated, and equipment designs will be proposed, ensuring an economically viable process suitable for industrial-scale production. The SPAT-eCat project demonstrates the potential of electrified catalytic systems to revolutionize the production of adipic acid and other bio-based chemicals, offering a scalable, environmentally friendly alternative to traditional methods. By bridging the gap between laboratory innovation and industrial application, the project lays the groundwork for establishing flexible biorefineries capable of producing a wide range of bio-based chemicals. The successful implementation of this project could serve as a model for the chemical industry’s transition toward renewable and sustainable practices.
