Success Story No. 11: The FIREFLY Project

Greening the European Chemical Industry 

Context 

Europe is the second-largest chemicals producer in the world, according to the CEFIC Chemdata International. The chemical industry is not only vital to the European economy but also a crucial supplier for major key industrial sectors. Around 90% of chemical processes and 60% of all industrial products rely on catalytic processes. These chemical reactions rely on metals linked to the catalytic activity, most of them labelled as Critical Raw Materials (CRMs). As a result of high energy and raw material utilisation, the current production and recycling of catalysts mainly hinges on processes that are neither sustainable nor economically feasible. In the context of minerals supply shortages, strengthening the competitiveness of the European chemical industry needs increased metal recycling.

FIREFLY – a Processes4Planet Project

Funded by Horizon Europe under a Processes4Planet call, FIREFLY (FlexIble, predictive, and Renewable Electricity-powered electrochemical toolbox for a sustainable transition of the catalyst-based European chemical industry) kicked off on 1 January 2024. Proposing a pioneering technology, the FIREFLY project aims to electrify a large part of the chemicals value chain in a sustainable way (environmental, economic, and social): power-to-catalyst and chemicals fostered via electrochemical catalyst recycling. FIREFLY also aims to cut greenhouse gas emissions in the chemical sector by using renewable energy and sustainable recycling methods and replacing traditional, polluting processes with clean, energy-efficient technologies. To achieve its ambitious goals, the P4Planet project focuses on developing electro-driven metal recycling, integrating renewable electricity, creating predictive digital tools, and producing innovative catalysts to reduce emissions and improve sustainability in chemical processes.

A Potential Decarbonisation Tool for the Chemical Sector

Although young, the project shows potential to support the green transition of the chemical industry. FIREFLY conducts the integration of Renewable Energy Sources (RES) in the processing chain and manufacturing of (electro)catalysts from the said secondary resources. The innovative RES-powered technologies proposed by FIREFLY are expected to substantially reduce CO2 emissions across various industrial processes:

The expected results are 65% CO2 emisssion reduction compared to state-of-the-art recycling methods. Additionally, the new electrochemical production of ammonia could reduce emissions to just 0.2 tonnes of CO2 per tonne of NH3, compared to 2.2 tonnes using the traditional process. This represents a total reduction of CO2 emissions of about 90%.

Also, one of its electrochemical technologies, Electro-driven Solvoleaching (ESLX), has demonstrated a >85 % Pd (palladium) recovery (lab scale level) from the spent catalysts of the lignin depolymerisation process. Palladium is on the list of Critical Raw Materials of the European Commission.

Furthermore, electroleaching (ELX) - one of the numerous technologies explored in FIREFLY, aims to reduce water consumption by 60%, compared to the SoA processes.

This, paired with the high replicability of the solution, amplified through the team’s strategy to communicate, disseminate and exploit the activities and results of the project indicate that FIREFLY has the potential to become a valuable tool for the decarbonisation and competitiveness of the chemical sector.

Empowering Women and SMEs in Research and Leadership

On a societal level, FIREFLY aims to raise awareness of sustainability and innovation and highlight the role of renewable energy-powered electrochemical processes. Moreover, to achieve its ambitious goals, FIREFLY also hinges on inclusive innovation or collaborative impact, reflecting a commitment to fostering gender equity while supporting small and medium-sized enterprises (SMEs). The team has more than 30 women involved in research and management tasks (out of which nine are leading tasks related to research activities). The FIREFLY consortium includes six SMEs. “These efforts collectively contribute to societal well-being and the transition towards a sustainable future”, the project’s team told us.

A.SPIRE considers the FIREFLY project a success story, even at this early stage,  for its promising progress in advancing sustainable technologies, reducing emissions, and promoting inclusivity, reflecting its potential to transform the European chemical industry, bringing it one step closer to the Processes4Planet 2050 SRIA vision.

Download the leaflet for more information about the November Success Story. 

Visit the FIREFLY project’s website.

For more information about A.SPIRE, the Processes4Planet Partnership, and the Success Stories campaign contact the team.