MOLCAR Swiss Funds 2.0

The Project co-funded from the Swiss-Polish Cooperaion Programme via the National Centre of Research and Development https://www.gov.pl/web/ncbr

For more information on the programme, please visit:   https://www.programszwajcarski.gov.pl/en

Project description:

The project aims to develop and demonstrate an integrated system for the synthesis of Sustainable Aviation Fuels (SAF) through the combination of Molten Carbonate Electrolysis (MCE) and a modular Fischer–Tropsch (FT) reactor. The innovation lies in coupling high-temperature co-electrolysis of CO₂ and H₂O with a catalyst-optimised FT process to convert syngas into long-chain hydrocarbons suitable for SAF applications. To support this, the

consortium will advance a novel class of catalysts based on two-dimensional molybdenum carbide (2D-Mo₂C), offering an alternative to traditional cobalt or iron catalysts by improving tolerance to contaminants, reducing dependence on critical raw materials, and enabling tailored selectivity. The system will be designed to operate under compact, modular conditions using thermal integration between MCE and FT units.

The project is structured into 5 interdependent WPs, each logically sequenced to ensure progress among the tasks.

WP1 alternates laboratory measurements and simulation to establish a validated process model. Small-scale MCE tests at Fuel Cell Poland provide voltage, gas composition and thermal-gradient data; parallel micro-reactor experiments at ETH Zürich yield intrinsic FT kinetics. Both datasets populate an Aspen-Plus flowsheet containing a pseudo-two-dimensional cell-stack model for the MCE and a temperature-dependent plug-flow model for the FT reactor. Iterative adjustments reduce the discrepancy in calculated cell voltage to below five per cent, delivering a quantitative baseline for hardware sizing.

WP2 synthesises Mo₂CTₓ precursors via HF and molten-salt routes, converts them to pristine 2D-Mo₂C under controlled H₂ pretreatment and links vacancy density, inter-layer spacing and oxicarbide fraction to CO turnover frequency and C₈–C₁₆ selectivity. The best formulation is reproduced at kilogram scale and forwarded to Casale for 30 bar continuous-flow validation.

WP3 converts numerical specifications into engineering drawings for a 550 cm² MCE short stack and a 5 mL FT tube mounted on a common stainless-steel manifold. Pressure-retaining parts comply with EN 13445 and ASME VIII creep–fatigue criteria. Auxiliary skids for feed conditioning, oxygen removal and condensate handling are designed with redundancy to permit independent operation of each subsystem. A dedicated thermal-management study identifies the optimum distribution of radiant shields and recuperative exchangers, ensuring local temperatures remain within design limits during startup and load transitions.

WP4 executes a 1 000 h endurance campaign, the electrolyser runs at variable current densities while the FT reactor processes syngas matching real-time MCE output. Gas chromatography quantifies chain-length distribution, and simulated distillation confirms that at least 60 % of the liquid fraction lies in the C₁₂–C₁₆ jet-fuel window. Post-mortem microscopy and XPS on catalysts and electrodes provide degradation metrics.

WP5 extrapolates lifetimes with Arrhenius-type models, merges supplier quotations with scaling laws to generate CAPEX curves for 100 kW, 1 MW and 10 MW modules, and benchmarks energy demand, carbon-conversion efficiency and levelised SAF cost against published PEM-FT figures.

The MOLCAR project aligns with the Programme’s goals by developing a novel, scalable system for sustainable aviation fuel synthesis via integration of a molten carbonate electrolyzer (MCE) and a modular Fischer–Tropsch (FT) reactor. Using a next-generation 2D-Mo₂C catalyst and controllable syngas from MCE, the system enables stable, electrified fuel production from CO₂, even under fluctuating feed conditions. The project combines industrial research and experimental development, reaching TRL6, and brings together research institutions and SMEs in a strong Polish–Swiss partnership. MOLCAR addresses SDG 4, 5, 7, 8, 9, 12, 13 and 17, by fostering innovation, clean energy, climate action, inclusive education and gender equality, while supporting economic growth and long-term decarbonization of aviation through modular and scalable technology platforms.

Communication Objectives of the Project: The primary objectives are to raise awareness about the project's goals, progress, and outcomes; engage stakeholders and the public; and promote the benefits of the Research and Innovation Programme. Measurable targets include reaching a wide audience through online and offline channels, generating media coverage, and achieving high attendance at events. Target Audience: The target audience includes national, regional, and local stakeholders such as industry partners, policymakers, energy providers, researchers, and the general public. Strategy and Content: The communication strategy will involve a mix of activities and tools designed to maximize impact.