Agora Energy’s Solution Will Turn CO2 & Electricity Into Industrial Feedstocks Cheaply
This is the third in a series of articles I’m writing about flow battery technology, with a couple of articles devoted to Agora Energy Technologies’ specific technology. The first article dealt with flow batteries in general, and why they are a strongly promising component for grid storage. The second dealt with Agora’s unique differentiators. This article is devoted to a compelling alternative use case for their technology, one that’s immediate and high value.
The past three years have been a deeper dive into industrial processes and chemical engineering for me, and the implications for global warming. The CleanTechnica report on Carbon Engineering was a major effort, as were the many articles on industrial processes for carbon sequestration. The assessment of cement manufacturing, with and without the nonsensical use of concentrating solar power was another.
This has led me to a deeper interest in the edge cases of climate solutions. My assessments and research over the past few years has led me to understand the major solution sets for energy, transportation, and biological carbon sequestration, but there’s still a lot of carbon and pollution emitted in industrial processes that needs to be addressed. As one example, there is the $44 billion global carbonates market.
Potassium carbonate is in a lot of things we use daily. It’s used in soaps, glass, and china dishes. It’s used as a drying agent in chemical processes. It’s in both Asian noodles and Dutch cocoa powder. Wine makers use it. It’s a water softener and a fire extinguisher. It’s used in welding and animal feed.
Sodium carbonate is equally widely used. It’s in glass, paper, rayon, soaps, and detergents. It’s used for water softening. It’s a food additive that controls acidity. As a weak, safe to handle base, it’s used in a lot of chemical processes. Over 40 million metric tons are produced each year, amounting to several kilograms for every person on Earth.
Between them, they represent a roughly $44 billion global annual market. And the current processes that make them are pretty nasty in a lot of ways.
Let’s take sodium carbonate as an example. About 75% of all the sodium carbonate used in the world is made by the Solvay Process. The US gets most of its sodium carbonate from a massive trona deposit in Wyoming.
Syracuse Solvay process works circa 1900 courtesy US Library of Congress
The Solvay Process was invented in 1861, and is still used everywhere today. It bubbles CO2 up through ammonia-based brine in a four-step chemical engineering process that produces and uses CO2 at various points in the process. And of course there’s the ammonia, which is highly toxic, with 15-minute exposure limits to levels of 35 ppm of gaseous ammonia per the US Occupational Safety and Health Administration. Ammonia is a manufactured substance in and of itself, using hydrogen created from fossil fuels today with 8-35 times the mass of CO2 as hydrogen. Prolonged exposure to small amounts of ammonia cause irreversible health effects. The ammonia is mostly recycled with only small amounts being lost, but eliminating it entirely would be beneficial.
The Solvay process actually captures some CO2 produced in one step to use in a later stage, but overall, the deployed process is a net emitter of 2.74 times the mass of CO2 as the mass of carbonates produced.
Solvay chemical process flow courtesy of UN IPCC
The source of heat in the first step interested me. That step in the process is the same as for cement, incidentally. It requires substantial heat, in the 600 to 1000 degree Celsius range to calcinate limestone to make quicklime and CO2. Some of the CO2 and all of the quicklime are used in later steps in the process, unlike cement making where all the CO2 is just emitted into the atmosphere.
As a side note, a Lafarge cement expert told me when I was exploring cement that they had no good process for capturing limestone kiln CO2 emissions, which clearly isn’t the case as it has been done as an industrial process for 160 years. Capturing flue CO2 isn’t hard, it’s just expensive, so it isn’t done unless there’s a very good economic reason.
Then there’s another temperature challenge, which is that the third step in the process is strongly exothermic, which means it gives off a lot of heat, just not usefully. One of the key challenges in the process is keeping the temperature low enough. That’s typically done with cooling water from ground sources, a challenged source in many parts of the world today, with thermal generation plants shutting down or running on diminished capacity as ground water heats up past the point where it works well with the designed equipment. The Solvay company shut down four of its 22 Sao Paulo, Brazil units due to the river they take water from drying up in 2014, a taste of the future for many heavy water consuming industrial plants located on water sources at risk from global warming.
The second instance of the application of heat in step 4 is also interesting. That requires another kiln with a temperature of about 300 degrees Celsius. Any time I see heat these days in industrial processes, I assume it’s coming from fossil fuels, and I was unsurprised to find that the preferred energy source for the Solvay Process was coke, a processed coal derivative.
That’s not all of course. The Solvay Process is much less polluting than the Leblanc Process it replaced, but inland sites end up with 50% more waste deposits of by-products than the sodium carbonates of value. Solvay, New York, which was renamed when the Solvay company built a plant there, has massive waste beds that have polluted the local area and contributed to the nearby Onondaga Lake being declared a Superfund Site.
Long wall trona mine image courtesy Government of Wyoming
I haven’t done the same assessment of the environmental impacts of the US trona mining and processing sodium carbonate stream, but at first glance it looks like a high CO2 emitter with a fair amount of use of toxic chemicals and a challenging waste stream as well.
Why is this digression interesting? Well, the Agora technology can create sodium carbonate in two steps without any heat and with barely any temperature management required.
Wait. What? It’s a battery, not a chemical plant, isn’t it?
Well, yes. The closed-loop model cycles the chemicals between their base form and their charged form and back. But the open-loop model, which changes in some of the details, produces sodium carbonate after the second cycle instead of turning it back into CO2, in a up to 35% by weight solution with water. And both act as batteries, taking in electricity in the charging stage and producing electricity in the discharge phase.
So the ammonia-based, high-heat, high-cooling, five-step process turns into a shorter process with much less harmful outcomes. It takes electricity when it’s cheap at night or other times, from renewables wherever possible of course, to ‘charge’ the battery. Then during the daytime, instead of reversing the process as in the open-flow approach, it sends it through Agora’s cells with a different chemistry and produces carbonates in solution and electricity. The entire daytime process from lights to pumps to drying the carbonate solution and the like can be run by a portion of the electricity that’s produced.
The output sodium carbonate is pure as well. It’s a pure compound in pure water. Heat the water to evaporate it off, and the purity should be well over the 98% purity typically guaranteed for food additives for the most expensive variants. There’s enough electricity in the battery to power the evaporation directly per my calculations with the CEO Dr Christina Gyenge, but there’s far more than enough to use heat pump technology with a COP of 4 to do that, or to pump it over a source of waste industrial heat elsewhere, and leave a lot of electricity left over for other uses in the industrial facility or to sell to the grid.
So, this technology can take a cheap feedstock we have too much of in the world, CO2, regardless of where it comes from and using renewable electricity produce very high quality industrial chemicals that are used globally in a market worth tens of billions of dollars.
Agora’s CO2-based redox flow battery technology is an industrial component from the future.
Full disclosure. I have a professional relationship with Agora as a strategic advisor and Board observer. I did an initial strategy session with Agora about their redox flow battery technology in late 2019 and was blown away by what they had in hand, and my formal role with the firm started at the beginning of 2021. I commit to being as objective and honest as always, but be aware of my affiliation.
Autonomous taxi company Waymo faced scrutiny last month when a car was caught on video illegally passing a stopped school bus that was letting children off in Atlanta. Now, the National Highway Traffic Safety Administration (NHTSA) is looking into it.
Georgia State Representative Clint Crowe seemed stunned after being presented with video of a Waymo driverless car illegally passing a stopped school bus on Briarcliff Road in Atlanta last month. “I’m a big fan of new technologies and emerging technologies and I think that driverless cars are going to become more prevalent,” he told local NBC news affiliate WBIR. “But we got [sic] to think about how they’re going to comply with the law.”
WBIR | Waymo illegally passes school bus
Crowe co-sponsored Addy’s Law in 2024. The legislation was named after 8-year-old Addy Pierce, who was killed in Henry County after being struck while crossing the street to get to her bus. The law stiffened penalties for illegally passing a stopped school bus, carrying penalties of up to $1,000 in fines and even jail time.
According to Crowe, those rules still apply to autonomous vehicles. “The majority of our traffic laws, the penalty is usually a fine and or driver’s license suspension. These cars don’t have a driver, so they don’t have a driver’s license and so we’re really going to have to rethink who’s the responsible party, who’s going to be responsible for being in control of that vehicle and who’s going to be the operator of that vehicle,” he said.
Crowe believes manufacturers should face stronger consequences when their vehicles break the law, saying the $1,000 fine doesn’t go far enough.
Now, thanks to pressure from social media and politicians like Crowe and Geoirgia State Senator Rick Williams, who helped co-author Addy’s Law, it seems like NHTSA is getting involved.
Prompted by media reports, the US Department of Transportation issued an investigation regarding Waymo’s AV, which states that, “the AV initially stopped, but then drove around the front of the bus by briefly turning right to avoid running into the bus’s right front end, then turning left to pass in front of the bus, and then turning further left and driving down the roadway past the entire left side of the bus. During this maneuver, the Waymo AV passed the bus’s extended crossing control arm near disembarking students (on the bus’s right side) and passed the extended stop arm on the bus’s left side.”
While it remains to be seen how much work NHTSA is actually doing amid the ongoing shutdown of the Federal government, it’s worth noting that, regardless of the outcome, Senator Williams said he plans to introduce new legislation that would hold driverless car companies accountable with higher fines if their vehicles violate traffic laws. If that passes in Georgia, it could set the stage for politicians across the US and even abroad to use similar fins to halt the spread of autonomous taxis in their states.
“Driverless cars should be stopped until it can be figured out,” said Williams. “We should not have this on the road. It’s too dangerous for our children.”
You can read NHTSA summary, below.
We’re typically pretty tech- and autonomous-forward here, but as a parent I would absolutely lose my s*** if a Waymo or Robotaxi or whatever else ran over my kid. but I’ve also seen plenty of human drivers blow past a school bus with a knee on the steering wheel and both eyes glued firmly to their phones. Let us know who you’d be more ready to trust with your kids’ lives in the comments.
SOURCES: WBIR, NHTSA, via School Transportation News.
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![Lion Electric school bus warranties voided, leaving districts stuck [update]](https://i0.wp.com/electrek.co/wp-content/uploads/sites/3/2025/07/unforgivable.jpg?resize=1200,628&quality=82&strip=all&ssl=1)
Nobody ever says “this is business” before doing something nice, and the recently reborn Lion Electric company is keeping that streak alive by doing the unthinkable to cut costs: they’re going to void the warranties on hundreds of electric school buses.
UPDATE 01NOV2025: two Lion Electric buses caught fire, now they’re in more trouble.
This past summer, the fallout from Lion Electric’s dissolution reached a critical mass, and the company’s new owners — the Quebec-based real estate giants Groupe MACH — decided to cancel the warranties on electric school buses sold in the US, leaving many districts with unsafe or broken down buses and no recourse to get their money back while the brand continued to take orders and make money in Canada.
Now, it seems like even the Canadian fleets have some serious safety concerns. School Transportation News and the CBC report that The Quebec Ministry of Education has ordered Lion school bus models be taken out of service immediately after a pair of LionC electric buses caught fire in Montreal, Quebec on Sept 9th, leading to disruptions across the province and a renewed scrutiny of Lion bus safety (Lion360 diesel-powered school buses, which Lion manufactured prior to only producing electric vehicles in 2017, were also affected by the issue).
Lion Bus (the company’s new, official name), has issued an inspection bulletin detailing a four-hour repair, which reads, “We have identified some potential anomalies in a sub-component of the HVAC system that Lion obtains from a third-party supplier … in the interest of safety above all else, we request that Lion bus operators perform the following inspections and modifications: mandatory inspection of several low-voltage electrical connections, replacement of certain electrical connectors, replace fan fuses with less powerful ones, adding a fuse to an HVAC control panel circuit. This inspection and modification procedure must be carried out on all Lion360 (diesel) and LionC 3rd generation and earlier buses (Gen3, Gen2 and Gen1).”
No word yet on whether the issue impacts any of the few Lion Electric buses still on US roads, but remember: Lion Bus wouldn’t help you if it did.
You can read about Lion’s decision to leave US school districts holding the bag on its troubled products in the original July post, below, then let us know how you feel about Groupe MACH’s handling of the situation in the comments section at the bottom of the page.
The warranty story
In a letter issued to exiting Lion Electric customers last week, Deloitte Restructuring announced that the warranties on all Lion vehicles purchased outside of the company’s home Province of Quebec are null and void – leaving dozens of school districts in the lurch with stranded assets that won’t get fixed, and can’t be sold to generate funds for replacements.
“We are working with alternate vendors at the expense of the school district to help keep our electric buses functional and on the road,” explains Dr. Richard Decman, Superintendent of Herscher CUSD No. 2 district in Herscher, Illinois. “Currently, six of our 25 (Lion) electric buses need some type of repair.”
Student Transportation News reports that Lion buses represent fully half of Herscher’s overall fleet of 50 buses, and that the district has received nearly $10 million for the purchase of 25 electric buses and the related charging stations from various state and utility incentive programs.
Herscher isn’t the only district having problems with Lion buses. “All four Lion buses that we own are currently parked and not being used,” Coleen Souza, interim transportation director of Winthrop Public Schools, told Clean Trucking. “Two of them are in need of repairs which would cost us money which we are not willing to invest in because the buses do not run for more than a month before needing more repairs.”
More of the same in Maine, where Yarmouth School Department bought two Lion Electric buses in 2023 with the state covering the costs. According to Superintendent Andrew Dolloff, the buses almost never worked. “We’ve had some sporadic service over the past two years, but as soon as the tech leaves, the buses produce error codes again,” explained Dolloff. ” and “Then the technician quits or is released, and we wait a few months for the next response.”
Dolloff added that Yarmouth’s electric buses did not operate during the 2024-25 school year.
Lion’s new owners are seemingly uninterested in their customers’ plight – which might be easily dismissed if those new owners, Groupe MACH, weren’t also the old owners of Lion Electric.
That’s right, kids. Quebec-based real estate company Groupe MACH, which stepped in to “save” Lion Electric earlier this summer, along with Ontario-based Mirella & Lino Saputo Foundation, bought $90 million of equity in Lion Electric back in 2023. And, while the MACH people may not have been the ones who ultimately made the call about voiding the warranties (that decision was made by the Deloitte bankruptcy team), it is absolutely Group MACH who have, to date, not announced plans to continue to honor those warranties, either.
Make of that what you will.
Deloitte Lion letter
SOURCES: School Transportation News, Clean Trucking, Deloitte.
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The first-ever Liebherr MK 120-5.1E electric crane in customer hands has rolled into the narrow, historic streets of Bern’s old town at 20 meters tall with a 45 meter reach and (of course) zero emissions, no vibrations, and almost no noise.
Deployed by Swiss construction firm Zaugg AG Rohrbach, the new Liebherr electric mobile crane is working hard placing temporary roofs above operational construction sites. It’s precise work, since the narrow streets of Bern’s historic old town weren’t even built for cars — much less massive, five-axle construction machinery. The prices controls and smooth operation of the electric drive mean the MK120-5.1E’s operators could confidently navigate the narrow streets without causing damage and creating new, unpaid jobs for themselves.
“The all-wheel steering allows us to manoeuvre easily in the narrow alleyways,” explained Stefan Stettler, head of the crane department at Zaugg AG Rohrbach. In reverse gear, the crane worked its way along the historic Rathausgasse to its construction site, past the arcades typical of the old town.
In addition to on-board power, the mobile crane can also be plugged into on-site grid power where available, or any mobile power sources capable of offering a steady 63 AMP output for lifting work. A mobile Liebherr Liduro Power Port LPO 100 was on hand in Bern, made available to Zaugg expressly for this purpose. With the Liduro LPO 100 fully charged, Liebherr says the stored energy is good for two full days of crane work.
“The low-noise and emission-free crane work is naturally pleasant for (Bern’s) residents, tourists and passers-by,” explained Stettler. “Especially as we only extended the crane support on the side facing away from the construction site by 50 per cent, allowing pedestrians and cyclists to pass through at all times.”
The MK120-5.1E electric mobile crane offers 8,000 kg (~17,650 lbs.) of lifting capacity, and all of the crane’s drives and winches are powered by electric motors, eliminating both the need to “warm up” or service oil-based hydraulics. It can be had with either a 98 kWh on-board battery (shown) or a 544 hp Liebherr diesel genset.
Electrek’s Take
From compact wheel loaders to radical two-wheeled dumper concepts to massive battery electric retrofit excavators, Liebherr is absolutely killing it in the heavy equipment electrification race. Their electric equipment offerings are proving that EVs can get even the heaviest jobs done, and save big fleets even bigger money while doing it.
SOURCE | IMAGES: Liebherr, via Construction Equipment.
If you’re considering going solar, it’s always a good idea to get quotes from a few installers. To make sure you find a trusted, reliable solar installer near you that offers competitive pricing, check out EnergySage, a free service that makes it easy for you to go solar. It has hundreds of pre-vetted solar installers competing for your business, ensuring you get high-quality solutions and save 20-30% compared to going it alone. Plus, it’s free to use, and you won’t get sales calls until you select an installer and share your phone number with them.
Your personalized solar quotes are easy to compare online and you’ll get access to unbiased Energy Advisors to help you every step of the way. Get started here.
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