FORMSCALE - Accelerating the Transition of Electrochemical CO2 Conversion from Lab to Market
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Abstract
FORMSCALE delivers a disruptive electrochemical (EC) technology to convert CO2 into renewable formate and syngas, 2 versatile, storable products for the clean energy and chemical sectors. The project aims to validate a 500 cm² low-temperature EC reactor at Technology Readiness Level (TRL) 4, operating at industrial current densities with no need for external hydrogen or purified CO2. Fully compatible with renewable electricity and CO2 from biogas, FORMSCALE supports the decarbonization of hard-to-abate sectors, aligning with the EU Green Deal and RePowerEU. The innovation is based on critical raw material (CRM)-lean CuSn gas diffusion electrodes (GDEs) and a tunable EC system capable of switching between formate and syngas via adjustable operating conditions.
Advanced multiphysics modeling and durable GDEs enable scalability and long-term operation. FORMSCALE directly addresses the key barriers of CO2-to-X technologies: energy intensity, instability, and high costs. Preliminary techno-economic analysis confirms market readiness. Using CO2 from biogas and industrial-scale key performance indicators (KPIs), formic acid can be produced at costs up to 85% lower than current market prices, and syngas production remains competitive with fossil-based benchmarks. Commercial viability is reinforced through a structured go-to-market strategy, covering intellectual property protection, regulatory mapping, and stakeholder engagement. The system’s modularity and competitive cost make it attractive for decentralized applications such as biogas upgrading, industrial symbiosis, and power-to-fuel hubs. FORMSCALE will set a new benchmark for sustainable carbon valorization, combining scientific excellence, manufacturing readiness, and business-driven innovation. Its outcomes position the team for EIC Transition scale-up, private investment, or licensing opportunities, contributing to EU leadership in circular carbon and energy transition technologies.
People involved
- Hilmar Del Carmen Guzman Medina (Principal Investigator)
- Mohsen Mansourkiaei (Component of the research team)
- Domenico Ferrero (Responsabile Scientifico di Struttura)
- Chiara Ravetti (Responsabile Scientifico di Struttura)
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ERC sectors
Sustainable Development Goals
Budget
| Total cost: | € 90,000.00 |
|---|---|
| Total contribution: | € 90,000.00 |
| PoliTo total cost: | € 90,000.00 |
| PoliTo contribution: | € 90,000.00 |