Upscaling of Super Activated Carbon (SAC) from lab scale to prototype scale

UNs climate report clearly states that CO2-emissions must be a priority going forward. On a world basis, the emissions need to be significantly reduced, and the production of renewable energy similarly increased to replace the main CO2-producing energy sources. Industry, climate, and energy is also a focus in the European Green Deal. Environmentally sustainable energy sources such as solar and wind power will continue to be extremely important together with efficient, affordable, and environmentally sustainable energy storage solutions.

Beyonder’s self-developed technology is a hybrid energy storage solution, combining the benefits of a Supercapacitor and a conventional Lithium-ion battery. One of the main raw materials used for the technology is Super Activated Carbon (SAC), which Beyonder also has developed in-house. What makes this unique is the fact that the SAC replaces the rare metals cobalt and nickel, which is used in conventional Li-ion batteries.

This results in a Lithium-ion Capacitor, similar to a battery cell, with high effect, long lifetime, high safety, and with a lower environmental footprint.

Beyonder is leading this innovation project to upscale their developed technology from lab scale to prototype scale. They are planning for full scale production of their Lithium-ion Capacitors by end of 2024, which will require 2.5 tonnes SAC per day. Today, in the lab, Beyonder produces 500 grammes per batch.

Through this project, the aim is to upscale the different processes developed in the lab while upholding the high quality of the end product. This is a large project that Beyonder cannot carry out by themselves, so it has been crucial to find the right collaboration partners.

Tschudi Bio Company will collaborate on the full-scale production of Super Activated Carbon by using sawdust from Bergene Holms sawmill in Haslestad. WAI Environmental Solutions AS holds test facilities in addition to having solid experience in developing advanced machinery and production lines. Universities and other research facilities are also an important resource in innovation projects, and Beyonder is very happy to be collaborating with NTNU in Trondheim and Karlsruhe Institute of Technology in Germany.

This project is the start of a larger and more long-term plan to establish a Super Activated Carbon factory in Vestfold, near the sawmill of Bergene Holm in Haslestad. The factory will be financed and run by a shareholder’s agreement between Beyonder, Tschudi, and WAI. The first years, Beyonder will be the main customer, but there are also possibilities to expand into other industries and application areas.

Follow us on this exciting journey towards a more environmentally sustainable industry!

Partners: NTNU, Karlsruhe Institute of Technology (Germany), Tschudi Bio Company, WAI Environmental Solutions AS og Bergene Holm