REBEL Development of a sustainable process and a high-efficiency electrified catalytic reactor for synthesis of biofuels from syngas
• KT Tech S.p.A. (KTT, Coordinator)
Technology owner, pilot plant engineering and construction
• Nextchem S.p.A. (NXC)
Technology conceptual development, pilot plant operation, technology assessment
• Università degli Studi di Salerno (UNISA)
Catalyst tests and lab-scale validation, electrification of catalyst for pilot plant
• Consiglio Nazionale delle Ricerche (CNR-ITAE)
Catalyst up-scaling for pilot plant
Project funded by the Italian Ministry of the Environment and Energy Security under the Mission Innovation 2.0 initiative
The REBEL project proposes an innovative and sustainable process for the synthesis of biofuels from biogas, consisting macroscopically of two steps: an electrified biogas reforming step, followed by a biofuel synthesis step (bio-methanol, SAF: Sustainable Aviation Fuel).
REBEL aims at validating at pilot scale (TRL7) a reactor already developed at TRL4 for the reaction of electrified methane reforming, innovative compared to the conventional reactors in which the heat of reaction is supplied by gas combustion, with the connected emissions of CO2. Moreover, the proposed technology, unlike the systems that use only the biomethane derived from biogas, allows the conversion of the CO2 contained in the feedstock, enabling its valorization and reduction of emissions in atmosphere.
The overarching goal of the project is to develop a biogas exploitation technology that is compatible with conventional synthesis processes and promotes decentralized production of carbon-neutral synthetic biofuels. This is achieved by using renewable feedstocks (biogas) and avoiding CO₂ emissions associated with process heating (via the electrified reformer). The REBEL project can support the development and valorization of the biogas sector — highly promising in Europe and currently driven mainly by subsidies — by fostering an Italian and European value chain that transforms local resources (agricultural waste, agri-food residues, and organic waste) into high-value-added products.
The project includes the development of process schemes integrating the electrified reformer with biofuel synthesis technologies (SAF and bio-methanol) aiming to identify and analyze synergies. The goal is to develop simple plant configurations that are easily adaptable to various plant capacities for the biogas exploitation and capable of maximizing process efficiency to produce sustainable and market-competitive biofuels.
Bio-hydrogen and bio-fuels
From TRL 4 to TRL 7
>10 Nm³/h (synthetic) biogas gas input
≥65% versus fossil fuels (RED compliance), including reduction of CO2 emissions versus conventional reformers and emissions from fossil fuels combustion
• Land valorization in terms of higher energy independence, allowing to reduce the need for the import of fossil fuels and enabling effective decarbonization thanks to the biological origin of biogas territory
• Enhancement of circular economy, thanks to the local valorization of agricultural waste (or Organic Fraction of Municipal Solid Waste)
• Optimization of the resources, increasing sustainability and efficiency of the industrial process
• Reduction of the environmental impact, the process includes the conversion of the biomethane fraction of the biogas as well as the CO2 contained, allowing its valorization and avoiding its emission in atmosphere
The REBEL project, developed by KT Tech and NEXTCHEM in collaboration with the University of Salerno and the CNR (Consiglio Nazionale delle Ricerche) proposes a process with zero carbon footprint for the delocalized production of biofuels from biogas.
The process is composed of two main steps: the electrified reforming of biogas and the following synthesis of biofuels starting from syngas. The main strengths of the proposed solution are:
- Valorization of local resources, such as agricultural and organic waste, for the production of biogas
- Utilization of renewable feedstocks like biogas, valorizing not only the biomethane but also the CO2 content, allowing its conversion in the reforming reactor and avoiding its emission in atmosphere
- Electrification of the reforming reactor that allows to supply heat to the endothermic reaction with renewable electricity, avoiding combustion of hydrocarbons with the connected CO2 emissions
- Delocalization of biofuels production that allows to exploit renewable resources available on the territory
The core of the project is an innovative electrified reforming reactor that allows to supply heat to the endothermic reactions (biogas reforming) avoiding the combustion of fuels and therefore the connected emissions of CO2.
The project proposes the reforming of biogas, allowing the valorization of both the biomethane and the CO2 contained in the renewable feedstock, utilizing the electrified reactor and therefore reducing the CO2 emissions compared to conventional processes. The syngas generated by the reforming is utilized for the synthesis of biofuels, such as biomethanol and SAF (Sustainable Aviation Fuel).
The REBEL Project is structured into five Work Packages (WPs), each dedicated to a specific phase of the project activities. These work packages allow the division of the work in a structured way, starting from the definitions and specifications, to the development and optimization of the catalyst, to the core activities such as the realization of the pilot plant for the validation of the technology, that goes in parallel with the techno-economic and environmental evaluations on the industrial scale process. The following sections provide a brief overview of each work package, outlining their primary focus.
- WP1 – Specifications and process definition (NEXTCHEM): Specifications on inputs and products, definition of representative industrial plant scale, development of schemes and process simulations (pilot and industrial scale)
- WP2 – Optimization and scale-up of structured electrified catalyst (UNISA): Scale-up of the structured electrified catalyst to be tested on the pilot unit (TRL 7)
- WP3 – Reforming pilot unit – design, construction, test and post-analysis (KTT): Construction of the pilot plant at NextChem’s Green Innovation District in Rome, operational testing for a period of 2000 hours
- WP4 – Impact of the technology on industrial scale (KTT): Techno-economic analysis, life cycle assessment, and exploitation strategy for the technology
- WP5 – Communication & Dissemination (NEXTCHEM): Communication and dissemination plan for the technology, interaction with the scientific community and stakeholders, promotion of the technology
- Validation at TRL 7 of the technology proposed for the electrified reforming of biogas into syngas
- Operation of the pilot plant for 2000 hours, production of at least 20 Nm3/h of syngas with a composition suitable for the synthesis of biofuels, reformer thermal efficiency > 90%
- Assessment of technology feasibility from technical, economic, and environmental perspectives
- Reduction of 65% of CO2 emissions compared to the conventional reformer
- Definition of market strategies for the commercialization of the technology
- Number of hours of operation of the pilot plant at TRL 7: 2,000 (intended as hours for parameter optimization + syngas production)
- Target cost of production of SAF: 3.000 €/ton (comparable with main alternative of biofuels from HEFA)
- Target cost of production of methanol: 1.400 €/ton (comparable with current reference)
- Quality of syngas product (H2/CO molar ratio at the outlet of pilot reforming reactor): > 90% of theoretical value at thermodynamic equilibrium
- Efficiency of biogas reforming stage, in terms of CO2 conversion (TRL 7): > 60%
- Biofuels carbon footprint reduction of at least 65% compared to fossil alternative
- Energy efficiency increase of the reforming step >10%
The project is funded by the Italian Ministry of Environment and Energy Security (MASE) in the framework of the Mission Innovation 2.0 initiative, promoting Research, Development and Technological Innovation Projects in line with the objectives of the Clean Hydrogen Mission (CHM) and of the Green Powered Future Mission (GPFM) - DM 386/2023.
Total project cost: €4,175,215
Funding: €3,057,389.75
Get in touch with Project team
Methanol
Complete portfolio for conventional, blue and green methanol
SAF
Actionable solutions for low-carbon transport