Catalysis is a core area of science that lies at the heart of the chemicals industry - an immensely successful and important part of the overall UK economy, where in recent years the UK output has totalled over £50B annually and is ranked 7th in the world. This position is being maintained in the face of immense competition worldwide. For the UK to sustain its leading position it is essential that innovation in research is maintained, to achieve which the UK Catalysis Hub was established in 2013; and has succeeded over the last four years in bringing together over 40 university groups for innovative and collaborative research programmes in this key area of contemporary science. The success of the Hub can be attributed to its inclusive and open ethos which has resulted in many groups joining its network since its foundation in 2013; to its strong emphasis on collaboration; and to its physical hub on the Harwell campus in close proximity to the Diamond synchrotron, ISIS neutron source and Central Laser Facility, whose successful exploitation for catalytic science has been a major feature of the recent science of the Hub. The next phase of the Catalysis Hub will build on this success and while retaining the key features and structure of the current hub will extend its programmes both nationally and internationally. The core activities to which the present proposal relates include our coordinating activities, comprising our influential and well attended conference, workshop and training programmes, our growing outreach and dissemination work as well as the core management functions. The core catalysis laboratory facilities within the research complex will also be maintained and developed and two key generic scientific and technical developments will be undertaken concerning first sample environment and high throughput capabilities especially relating to facilities experimentation; and secondly to data management and analysis. The core programme will coordinate the scientific themes of the Hub, which in the initial stages of the next phase will comprise: - Optimising, predicting and designing new catalysts - Water - energy nexus - Catalysis for the Circular Economy and Sustainable Manufacturing - Biocatalysis and biotransformations The Hub structure is intrinsically multidisciplinary including extensive input from engineering as well as science disciplines and with strong interaction and cross-fertilisation between the different themes. The thematic structure will allow the Hub to cover the major areas of current catalytic science

The European polymer industry is under increasing pressure to produce innovative products at lower cost to compete with overseas imports. Econic Technologies has invented a catalyst that enables replacing up to 40% of petrochemical feedstock in the production of polyurethane polyols, an important polymer segment, with low cost waste CO2, resulting in high performance product. Econic Technologies is spun out of Imperial College London, where the technology was invented, now grown to a family of patent-protected catalysts whose unique characteristic is high reactive activity and selectivity for polymers under low pressures. The catalysts enable the maximum theoretical uptake of CO2 with far superior reaction rates than their competitors under industry relevant conditions. The Econic catalyst creates novel value-add polyol building blocks for polyurethanes whilst offering significant feedstock savings: CO2 costs $100/Tonne whereas PO costs $1900/tonne. When competitive technologies require expensive new plant facilities to meet stringent process conditions Econic’s catalyst can be deployed by a low cost retrofit. The technology is proven in the lab (TRL6) and client-site demonstration (TRL7) has commenced on small scale. The Phase I feasibility study has established that early adopting market leading polyol producers are keen to deploy the technology but they still need to persuade their downstream customers, the polyurethane producers. This will crucially be assisted by demonstrator applications which Phase II will now develop. Over the first five years after Phase II completion, Econic generates EUR180m catalyst sale revenues. Polyol producers will benefit by increased profit margins to the tune of EUR380m over the same period. Catalyst toll manufacturers will generate turnover of EUR30m+ and carbon capture plants will be able to sell EUR18m worth of CO2. Total expected qualified job creation from the project exceeds 100 over the first five commercial years.

In the UK, the plastic industry alone employs >170,000 people and has an annual sale turnover of >£23.5 billion, it is also one of the top 10 UK exports. Worldwide polymer production volumes exceed 300 Mt/annum, with CAGR of 5-10%. Today almost all polymers are sourced from oi/gas and are neither chemically recycled nor biodegradable. Existing polymer manufacturing plants are optimized for a single product and because of the very high capital expenditure required to build plants their lifetimes must be as long as possible. One drawback of existing processes designed for a single product is that they hinder innovation and slow the introduction of step-change products. In this proposal a new manufacturing process allows monomer mixtures to be selectively polymerized to selectively deliver completely new types of sustainable materials. The process requires just one reactor which is re-configured to dial-up multiple combinations of desirable products with controllable structures and compositions. This fellowship allows time for detailed investigation and development of the manufacturing concept as well as new research into product applications in three high-tech, high-value sectors, namely as recyclable and biodegradable thermoplastic elastomers, shape-memory plastics for robotics and delivery agents for biomolecule therapies. The research is underpinned by the efficient use of renewable resources, such as carbon dioxide and bio-derived monomers, and the polymers are designed for efficient end-of-life recycling and biodegradation. By applying existing commodity monomers, such as propene oxide and maleic anhydride, industrialization and translation of the results is accelerated. The fellowship allows the PI to learn new skills and build collaborations which will be realized through regular sabbaticals and secondments. It also allows the close industrial collaboration and oversight to re-configure polymer manufacturing to produce sustainable, high value materials to meet existing and future industrial needs.

The OxICFM CDT, centred in Oxford University's Department of Chemistry, and involving eight key industrial stakeholders, two STFC national facilities, and faculty from Oxford Materials, Physics and Engineering seeks to address a UK-wide need for the training of doctoral scientists in the synthesis of inorganic materials relevant to the future prosperity of the manufacturing sector. Chemical synthesis is a key enabling scientific discipline that allows humanity to maintain and improve its quality of life. Within the UK, the EPSRC's own data show that the chemical/chemistry-using sectors contributed a total of £258B in value-added in 2007 (21% of UK GDP), and supported over 6 million UK jobs. Manufacturing processes and future materials are highlighted as key technologies in the recent UK Industrial Strategy green paper, and the long-term skills demand for scientists to develop new materials and nanotechnology was highlighted in the UK Government's 2013 Foresight report. The EPSRC's prioritisation in the area is highlighted by (among other things) the recent Future Manufacturing Hubs call. Future advances in societally critical areas such as petrochemical utilisation, battery technologies, semiconductors, smart materials, catalysts for chemical manufacturing, carbon capture, solar conversion and water supply/agro-chemicals are all underpinned by the ability to design and make chemical compounds and materials - to order - with custom designed properties. As an example, many technological developments in the last 30 years would not have been possible without Goodenough's fundamental work (carried out in Oxford) leading to the development of cathode materials for rechargeable lithium batteries - and ultimately to a $30B global industry currently growing at 10% per annum. We will exploit the uniquely broad range of excellence, innovation and multi-disciplinarity offered at Oxford by a critical mass of world-class researchers in this area (40+ faculty), to deliver a rigorous, challenging and relevant CDT programme in what is an under-represented area of graduate training. We believe that such a programme is not only timely and complementary to existing EPSRC CDT provision, but will address the national need for resilience, growth and innovation in key manufacturing sectors. The 'art and craft' of inorganic synthesis as applied to manufacturing is necessarily extremely diverse. OxICFM will exploit a cohort model allied to training incorporating faculty-, industry- and peer-led components, to deliver scientists (i) with a broad spectrum training across the interface between inorganic synthesis and manufacturing, and (ii) with in-depth expertise in one specific stream (molecular, nano-scale or extended materials). This model is driven by a strong end-user pull, including a desire expressed on numerous occasions by industrial partners, to recruit doctoral graduates who not only have depth of expertise in one area, but who can also apply themselves to a broad spectrum of inter-disciplinary challenges in manufacturing related synthesis with greater effectiveness than 'standard' doctoral graduates. As expressed by our SME partners and highlighted in Econic's letter of support: '(we do) not need lots more chemistry (post)graduates, we needed better prepared ones who could understand and adapt to working in industry more readily. I see a clear connection with the CDT intent and our own, and other scaling chemical businesses, needs.' With this clear vision in mind, a central component of our approach is the integration of industry-led training from both larger partner companies and SMEs in order to promote a holistic understanding of cross-scale issues relating to different business models. We stress that our aim is not to add significantly to total post-graduate numbers in Oxford Chemistry, but rather to provide a different training package to those currently available.

Over 90% of bulk polymers with a production volume of greater than 150 million tonnes per annum are sourced from crude oil. Within the UK, the polymers industry directly employs 286,000 people and has annual sales of £18.1 billion which accounts for 2.1% of UK GDP. It produces around 2.5 million tonnes of polymer every year and is achieving an annual growth of 2.5%. The UK is in the top 5 polymer producers in the EU and its exports are worth £4.6 billion to the UK economy. These polymers are ubiquitous in everyday life and have many applications including: medical, transport, electrical, construction and packaging; the latter accounting for over a third of all polymers produced. This dependence on petrochemicals for polymer production has environmental and economic risks and will, ultimately, become unsustainable as supplies of crude oil become exhausted. Therefore, there are good reasons to develop new processes for polymer production using renewable resources and for the UK, such resources must not compete with food production. Carbon dioxide is a particularly promising renewable resource, especially the use of waste carbon dioxide from sources such as power stations, chemical plants, cement and metal works. The overall aim of this project is to develop the chemistry and engineering required to transform waste biomass and carbon dioxide into commodity polymers (2011 global production 280 million metric tonnes), specifically: polyalkanes, polyethers, polyesters, polycarbonates and polyurethanes. The key reaction pathway is from biomass to alkenes (polymerizable to polyalkanes) to epoxides which can be polymerized to polyethers or copolymerized to produce polyesters or polycarbonates. These can be further reacted to produce polyurethanes suitable for applications in furniture, insulation and adhesives. For this to be sustainable, the alkene and other reactants must also be sustainably sourced and we will investigate the use of terpenes, sugar derivatives and unsaturated acid derivatives obtained from agricultural and forestry waste. For example, during the 2011-2012 growing season, the EU processed 1.9 million metric tonnes of citrus producing approximately 950,000 metric tonnes of waste. After removal of water this left 190,000 metric tonnes of residue from which about 14,000 metric tonnes of limonene could be isolated for use as a polymer feedstock. In addition to carrying out the required chemical research, the engineering necessary to scale up the syntheses to pilot plant and production scale will be carried out. The chemical and mechanical processes associated with isolating materials from biomass and converting them into polymers will inevitably require energy and other chemicals, the production of which will generate carbon dioxide. Therefore, lifecycle analysis will be used to determine all of the carbon dioxide emissions associated with polymer production from both petrochemical and biomass sources. Comparison of the data will provide a quantitative understanding of how much better the sustainable route is than the petrochemical route and will illustrate which aspects of the synthesis are responsible for most of the carbon dioxide emissions. This, combined with energy usage and cost data will allow the project team to concentrate their efforts on minimising these emissions through for example the use of microwave heating rather than conventional heating and the use of alternative solvents such as supercritical carbon dioxide. In summary, polymers are ubiquitous in everyday life and the polymer industry is a major UK employer. Their scale of production and range of applications means that they are a high priority target to switch from fossil to sustainable sourcing. Successful completion of this project will protect UK jobs, protect the UK supply of these essential materials and provide income through license agreements with overseas manufacturers.