Towards a sustainable winery: revalorization of green CO₂ for methane production

Abstract

The FUELPHORIA project explores innovative pathways for sustainable energy production, with DEMO 2 focused on transforming winery-derived CO₂ into methane (CH₄) using renewable hydrogen (H₂). Hosted at Viñas del Vero (VdV) winery in Spain, this demonstration integrates circular economy principles to mitigate emissions and produce renewable fuels.

The wine fermentation process at VdV generates approximately 520 tons of CO₂ annually, previously emitted to the atmosphere. A newly installed CO₂ capture and purification unit, capable of processing gas from 12 fermentation tanks and capturing up to 120 tons of CO₂ per season, purifies the gas to over 99% CO₂ purity for subsequent use. This CO₂ is fed into an advanced methanation reactor, where it reacts with green H₂ generated on-site via a photovoltaic-powered electrolyzer. The electrolyzer produces 500 liters per hour of H₂ with 99.94% purity and an output pressure of 30 bar. The methanation reactor, will have the capacity to convert the CO₂ and H₂ into high-purity CH₄ (exceeding 99%), with a production capacity of 2 kg/day.

The Key project objectives include: a) Designing and deploying scalable CO₂ capture and methanation systems compatible with winery operations, b) Developing nickel-based catalysts with enhanced stability and performance to maximize CH₄ yield and reduce side reactions, c) Demonstrating technology scalability through modular system designs, ensuring alignment with seasonal CO₂ availability., c) Experimental campaigns validated the catalyst’s long-term stability and conversion efficiency, achieving a Technology Readiness Level progression from 5 to 7 and d) The demonstration addresses logistical challenges unique to winery environments, such as seasonal CO₂ production, through flexible system integration.

By producing methane as a substitute for natural gas, DEMO 2 contributes to emission reductions, showcases the potential of renewable fuels, and exemplifies how industry-specific waste streams can be revalorized for sustainable energy production. This initiative demonstrates the feasibility of achieving carbon neutrality in the wine industry and serves as a replicable model for similar industrial symbiosis opportunities.

The present work will present the recent advances and developments installed during the DEMO construction VdV.

Figure 1. FUELPHORIA´S DEMO 2 process diagram.

Acknowledgements

Authors want to thank the EU. This research was co-funded by the European Union’s Horizon Europe Innovation Action HORIZON-CL5-2022-D3-02 (Sustainable, secure and competitive energy supply), under the “Accelerating the sustainable production of advanced biofuels and RFNBOs – from feedstock to end-use” (FUELPHORIA) project (Grant Agreement No. 101118286). Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or CINEA. Neither the European Union nor CINEA can be held responsible for them.