In brief
The SOFT project is developing innovative catalysts for the climate-neutral production of short-chain hydrocarbons (olefins) from CO₂ and green hydrogen using the Fischer-Tropsch synthesis. The aim is to replace fossil raw materials in the chemical industry and close carbon cycles by converting CO₂ into valuable chemical feedstocks, thereby sustainably reducing emissions and resource dependencies.
What we’re working on
Motivation
The project addresses the urgent need to decarbonise the chemical industry by developing a sustainable alternative to fossil-based production of short-chain olefins – carbon chains comprising 2–4 carbon atoms. These olefins are essential building blocks for plastics such as polyethylene and polypropylene, which account for 45 per cent of all plastics produced in Germany. Current production relies heavily on fossil resources with a high carbon footprint (1–2.5 kg CO₂/kg of product). The project aims to create a circular carbon economy by converting captured CO₂ and green hydrogen into these valuable chemical feedstocks via Fischer-Tropsch synthesis.
Innovative approach
The aim of the project is to develop novel iron-based catalysts that are specifically optimised for the selective production of short-chain olefins from CO₂ and H₂ via Fischer-Tropsch synthesis. The main innovations include:
- systematic catalyst development using co-precipitation, layered double hydroxides (LDH) and coating methods
- targeted promoter optimisation to increase olefin selectivity from the current 25 per cent to 40–60 per cent
- integration of product gas recycling
- Scaling up from laboratory to pilot scale (>100 kg) with a suitable catalyst formulation for industrial reactors.
Implementation and added value
The project paves the way for potentially significant economic and environmental added value by establishing German technological leadership in sustainable chemical production. It enables the utilisation of CO₂ as a carbon sink in long-lasting plastic products, supports the circular economy through waste-to-chemicals conversion and reduces dependence on imported fossil fuels. The collaboration strengthens German supply chains, from catalyst production (Clariant, Lanxess) through to end applications (Heide Refinery). Expected outcomes include new patents, the preparation of a new industrial process and, consequently, the positioning of Germany as a pioneer in sustainable industrial transformation.
SOFT in figures
Clariant’s Catalysts Business Unit develops, manufactures and markets technical catalysts for the chemical and petrochemical industries, as well as for applications in air purification, synthesis gas production and fuel processing. Under the motto ‘Greater catalyst. Smaller footprint’, sustainability is at the heart of its work: resource-intensive processes are made more efficient, emissions are reduced and the circular economy is promoted. The focus of Clariant’s project work will be on scaling up the catalysts developed to the multi-kg scale.
At its Krefeld-Uerdingen site, LANXESS has around 100 years’ experience in the production of iron oxides for pigmentary and technical applications. From the outset, research into iron oxides has been conducted in parallel, and the products have been adapted to their respective applications. As part of the project, LANXESS will synthesise various tailored iron oxides for catalyst production, further optimise them and subsequently scale them up to pilot plant scale (>100 kg).
With a capacity of 4.5 million tonnes of crude oil per year and a broad portfolio of petrochemical products, Raffinerie Heide supplies essential raw materials for everyday needs. The products are used in everyday items – from fuels to chemicals. As part of the project, Raffinerie Heide will carry out a technical assessment of the process integration into a refinery environment.
The Chair of Reaction Engineering at the TU Bergakademie Freiberg focuses, amongst other things, on the knowledge-based development and optimisation of heterogeneous catalysts for exhaust gas purification and synthesis processes. The focus of its involvement in the SOFT project lies on the development of olefin-selective Fischer-Tropsch catalysts, their extensive testing, and the optimisation of the operating conditions of the synthesis process.
The MPI CEC investigates the fundamental chemical processes involved in the storage and conversion of energy. The aim is to use the development of new and high-performance catalysts to store energy from renewable resources in such a way that it can be utilised independently of time and location. Within the project, the MPI CEC is working on the development of high-performance catalysts and their detailed investigation to assess their suitability for olefin synthesis from synthesis gas.
