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Breakthrough 3D Printing Technique Doubles Solar Fuel Efficiency
Until now, structures with isotropic porosity have been applied, but these have the drawback that they exponentially attenuate the incident solar radiation as it travels into the reactor. This results in lower inner temperatures, limiting the fuel yield of the solar reactor.
Breakthrough 3D Printing Technique Doubles Solar Fuel Efficiency
by Simon Mansfield
Sydney, Australia (SPX) Oct 30, 2023

In a major breakthrough that could revolutionize the production of solar fuels, researchers at ETH Zurich have developed a novel 3D printing methodology to create a reactor core with intricate, hierarchically ordered porous structures. These newly designed cores have shown to be particularly effective in optimizing the thermochemical process that produces synthetic fuels, thereby significantly boosting efficiency.

Engineers at ETH Zurich have been at the forefront of solar fuel technology, developing methods to produce carbon-neutral liquid fuels from sunlight and air. This technology was notably showcased in 2019 on the roof of ETH's Machine Laboratory, marking the first complete demonstration of the thermochemical process chain under real-world conditions. The resulting solar fuels are carbon-neutral, as they emit the same amount of CO2 during combustion that was initially captured from the air. Two ETH spin-offs, Climeworks and Synhelion, have been commercializing this technology.

A critical component in this production chain is a solar reactor. This reactor is positioned to receive concentrated sunlight from a parabolic mirror, reaching scalding temperatures up to 1500 degrees Celsius. It houses a porous ceramic structure made of cerium oxide, where a thermochemical cycle occurs that splits water and CO2 captured from the air. The outcome is syngas-a mixture of hydrogen and carbon monoxide-that can be further converted into liquid hydrocarbon fuels like kerosene for aviation.

However, traditional reactor cores with isotropic porosity were limiting the reactor's fuel yield. This structure caused a sharp attenuation of solar radiation as it moved deeper into the reactor, resulting in reduced internal temperatures.

Researchers from the groups of Andre Studart, ETH Professor of Complex Materials, and Aldo Steinfeld, ETH Professor of Renewable Energy Carriers, tackled this limitation by developing 3D-printed ceramic structures with unique pore geometries. Their innovative design channels solar radiation more efficiently into the reactor's interior, solving the previous issue of energy attenuation. The project has been supported by the Swiss Federal Office of Energy.

These new ceramic structures feature a hierarchical design with pores and channels that open at the surface exposed to sunlight and narrow down toward the rear of the reactor. This geometry allows the reactor to absorb concentrated solar radiation across its entire volume, effectively ensuring that the reactor reaches the necessary reaction temperature of 1500 degrees Celsius. To manufacture these structures, the team used a specialized, extrusion-based 3D printing process and an ink developed specifically for this purpose, which has a low viscosity and a high concentration of ceria particles.

Successful Initial Testing
In initial tests, the researchers explored the balance between radiant heat transfer and the thermochemical reaction within these new structures. They found that the 3D-printed cores could produce twice as much fuel as traditional isotropic structures under the same concentrated solar radiation-equivalent to the intensity of 1000 suns.

The technology has already been patented, and Synhelion has acquired the license from ETH Zurich. Aldo Steinfeld noted, "This technology has the potential to boost the solar reactor's energy efficiency and thus to significantly improve the economic viability of sustainable aviation fuels."

The development marks an important step in increasing the efficiency and economic viability of solar fuels, potentially accelerating their adoption in sectors like aviation that are difficult to electrify.

Research Report:Solar-driven redox splitting of CO2 using 3D-printed hierarchically channelled ceria structures

ai.energy-daily.com analysis

Relevance Ratings:

1. Energy Industry Analyst: 9/10
2. Stock and Finance Market Analyst: 8/10
3. Government Policy Analyst: 7/10

Analyst Summary:

Energy Industry Perspective:

The article describes a significant breakthrough in solar fuel production achieved by ETH Zurich researchers. The newly developed 3D printing technique to create solar reactor cores shows promise in doubling solar fuel efficiency. This innovation could have a substantial impact on the energy sector, especially in the race towards clean, carbon-neutral fuels.

Stock and Finance Market Perspective:

From a financial viewpoint, this technology is highly valuable. Two ETH spin-offs, Climeworks and Synhelion, are already commercializing solar fuel technology. The new advancement will significantly increase the sector's economic viability, making it an attractive investment opportunity.

Government Policy Perspective:

The Swiss Federal Office of Energy's support for the project underlines the state interest in advancing clean energy solutions. As governments worldwide push for sustainable practices, this breakthrough provides a compelling case for subsidies and policy frameworks to support renewable energy technologies.

Historical Context:

Over the last 25 years, the energy sector has experienced a steady push towards renewable sources, from solar and wind energy to biofuels. However, one major obstacle has been the efficient conversion of these energies into easily storable and transportable forms, like liquid fuels. This development in solar fuels echoes the earlier boom in shale gas technology, which also disrupted traditional energy markets but with a negative environmental impact.

Investigative Questions:

1. What is the projected cost of scaling up this 3D printing methodology to industrial levels?

2. How would this breakthrough impact existing renewable energy subsidies and government policies?

3. Are there potential limitations or bottlenecks in the supply chain for materials like cerium oxide, which is crucial for these 3D-printed structures?

4. Could the new technology be adapted for other forms of renewable energy or is it unique to solar fuel production?

5. What are the implications for carbon trading markets given that the solar fuels are carbon-neutral?

In summary, this article touches on technological, financial, and policy aspects that make it incredibly relevant across different analytical disciplines. Its potential to revolutionize solar fuel production makes it pivotal for future investments, policy-making, and energy sector developments.

Related Links
ETH Zurich
Bio Fuel Technology and Application News

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