Hybrid Multifunctional Catalysts for Advanced Biofuel Production

Towards High-Performance and Sustainable Catalysis

At the heart of FLEXBY’s innovation lies the development of catalysts designed to upgrade bio-oil and pyro-gas derived from pyrolysis processes. These catalysts play a key role in transforming biomass-derived intermediates into high-quality biofuels suitable for heavy transport sectors such as aviation and shipping.

The research covers the synthesis, characterisation, and lab-scale testing of these catalysts. The objective is to enhance conversion efficiency, improve fuel quality, and minimise environmental and economic costs—all while ensuring compatibility with a range of feedstocks, including microalgae, macroalgae, and industrial residues.

Two Families of Catalysts for a Flexible Biofuel Process

The study identifies two complementary families of catalysts; one designed for bio-liquid upgrading and another for pyro-gas processing:

• Bio-liquid Upgrading: The bio-liquid fraction produced through pyrolysis is typically rich in oxygen, which negatively affects its energy content and stability. FLEXBY’s team has explored hydrogen-free hydrodeoxygenation (HDO) processes that use water as both a solvent and a hydrogen donor, avoiding the need for costly external hydrogen. Preliminary tests using ruthenium-based catalysts on model compounds have shown promising results, demonstrating high conversion rates and improved biofuel quality. This hydrogen-free approach enhances process safety and cost-effectiveness while supporting the transition to sustainable fuels.
   
• Pyro-gas Processing: FLEXBY’s second catalyst family focuses on converting pyro-gas—comprising mainly hydrogen, carbon monoxide, carbon dioxide, and methane—into valuable energy products. Through combined Water-Gas Shift (WGS) and Steam Reforming of Methane (SRM) reactions, the project aims to maximise hydrogen recovery, a critical step toward renewable fuel generation. A thermodynamic analysis of the system has helped identify the optimal operating parameters, guiding catalyst design and ensuring efficient conversion pathways.

Scientific Progress and Circular Economy Principles

The project’s catalyst development is guided by strong sustainability principles. Instead of relying on non-renewable materials, among FLEXBY goals there is the use of biochar derived from waste biomass as a catalyst support material. This approach not only reduces raw material costs but also exemplifies circular economy practices, transforming low-value by-products into high-value components for green energy applications.

Extensive material characterisation using BET surface analysis, X-ray diffraction (XRD), and transmission electron microscopy (TEM) confirms the structural integrity and performance potential of the catalysts. Lab-scale tests have already shown high selectivity and conversion rates, marking a solid foundation for future upscaling.

Looking Ahead

FLEXBY’s catalysts are currently at Technology Readiness Level (TRL) 4. The next stage of work will focus on testing real bio-oil and bio-char samples derived from pyrolysis to refine catalytic formulations and validate performance under realistic conditions. These developments will pave the way for pilot-scale demonstrations (TRL 5) and eventual industrial deployment.

Catalysts for Change

By integrating advanced catalysis with sustainable process design, FLEXBY is contributing to the future of flexible, advanced biofuel systems capable of delivering high-quality, low-carbon fuels. This research strengthens Europe’s capacity to meet its energy transition goals, reduce dependence on fossil resources, and promote resource circularity.