Advancing E-fuels production through process intensification: overcoming challenges and seizing opportunities for a sustainable energy future - A critical review

Abstract

The global transition toward sustainable energy emphasizes e-fuels as a promising alternative to fossil fuels, particularly in sectors that are difficult to decarbonize, such as aviation and heavy industry. E-fuels are produced via the Power-to-Liquids (PtL) process, which converts renewable electricity into hydrogen through water electrolysis or other sources, such as methane or biogas reforming, followed by the synthesis of hydrocarbons and other carbon-based compounds using captured CO₂. Despite their potential, e-fuels face challenges such as high production costs and energy-intensive processes. Process Intensification (PI) offers a pathway to address these challenges by optimizing chemical processes to enhance efficiency, lower costs, and reduce environmental impact. Key areas of PI innovation include advancements in electrolysis technologies, catalyst development, reactor design, and carbon capture methods. These innovations are crucial for improving the efficiency of hydrogen and carbon-based fuel production, decreasing costs, and minimizing greenhouse gas emissions. Furthermore, PI facilitates modular and scalable production systems that integrate seamlessly with renewable energy sources, reducing the need for fuel transportation and associated emissions. This paper explores the challenges and opportunities presented by PI, emphasizing its critical role in advancing the production of e-fuels and positioning them as a key component of a low-carbon energy future.