Rohrdorfer Begins Ethylene Manufacturing from Carbon Dioxide

Rohrdorfer has successfully initiated the production of Ethylene from Carbon Dioxide (CO2) using a novel process. This innovative method captures CO2 generated during cement production and transforms it into ethylene. Following an initial test phase, the company plans to scale up production to an industrial level, advancing towards a comprehensive CO2 circular economy. Rohrdorfer's long-term objectives include achieving independence from fossil raw materials through regional value creation and advancing climate-neutral cement production. This initiative underscores their commitment to sustainable practices and reducing the environmental impact of cement manufacturing.

Rohrdorfer has leveraged its cement production CO2 to produce ethylene through a groundbreaking CO2 electrolysis technology. This innovative method not only generates ethylene but also produces formic acid and other hydrocarbons. By adopting the "CO2 to ethylene" approach, Rohrdorfer aims to establish a seamless circular economy, thereby reducing dependency on fossil raw materials and advancing towards sustainable production practices. This technology represents a significant step towards integrating carbon capture with valuable product synthesis.

The "CO2 to ethylene" initiative is a key component of the H2-Reallabor Burghausen – ChemDelta Bavaria research project, which involves 37 partners from industry, SMEs, startups, and research institutions. Launched in April 2023, this project aims to integrate hydrogen as a fundamental material in the chemical industry. Rohrdorfer's Net Zero Emission team dedicated several months to research and development based on their earlier "CO2 to formic acid" project. This effort enabled them to modify their plant to produce green ethylene. Initially, a test bench producing a few hundred grams of ethylene per hour has been operational, with plans to scale up to an industry-oriented demonstrator producing up to six kilograms per day. The next phase, set for 2026, aims to scale the process to convert 1 kilogram of CO2 per hour into ethylene on a container scale.

The plant's novel feature is its efficient operation at a pressure of 30 bar, which facilitates the straightforward filling of the product mixture into pressurized gas cylinders via a sampling point. This pressure level simplifies transportation to partners in the Burghausen H2 real-world laboratory. It also ensures that customers from the chemical triangle region can easily test and further process the ethylene, enhancing the plant’s operational efficiency and integration within the supply chain.

The Rohrdorf research project “CO2 to ethylene” is supported by a 50 percent grant from the Federal Ministry of Education and Research, with a total funding amount of €1.67 million. The project is set to span four years, highlighting the commitment to advancing innovative carbon capture and utilization technologies.

Dr. Alexander Beck, a member of the Net Zero Emission team at Rohrdorf, emphasizes the uniqueness of their carbon capture and utilization process, attributing it to a proprietary blend of pressure, large-scale production, and in-house technology. Leveraging their integration into the H2 real-world laboratory, the team is actively exploring avenues to maximize the value of captured carbon dioxide within the regional ecosystem.