Methylcyclohexane dehydrogenation for hydrogen production via a bimodal catalytic membrane reactor

The dehydrogenation of methylcyclohexane (MCH) to toluene (TOL) for hydrogen production was theoretically and experimentally investigated in a bimodal catalytic membrane reactor (CMR), that combined Pt/Al₂O₃ catalysts with a hydrogen‐selective organosilica membrane prepared via sol‐gel processing using bis(triethoxysilyl) ethane (BTESE). Effects of operating conditions on the membrane reactor performance were systematically investigated, and the experimental results were in good agreement with those calculated by a simulation model with a fitted catalyst loading. With H₂ extraction from the reaction stream to the permeate stream, MCH conversion at 250°C was significantly increased beyond the equilibrium conversion of 0.44–0.86. Because of the high H₂ selectivity and permeance of BTESE‐derived membranes, a H₂ flow with purity higher than 99.8% was obtained in the permeate stream, and the H₂ recovery ratio reached 0.99 in a pressurized reactor. A system that combined the CMR with a fixed‐bed prereactor was proposed for MCH dehydrogenation. © 2015 American Institute of Chemical Engineers AIChE J, 61: 1628–1638, 2015     

Characteristics of ammonia permeation through porous silica membranes

A sol–gel method was applied for the preparation of silica membranes with different average pore sizes. Ammonia (NH₃) permeation/separation characteristics of the silica membranes were examined in a wide temperature range (50–400°C) by measurement of both single and binary component separation. The order of gas permeance through the silica membranes, which was independent of membrane average pore size, was as follows: He > H₂ > NH₃ > N₂. These results suggest that, for permeation through silica membranes, the molecular size of NH₃ is larger than that of H₂, despite previous reports that the kinetic diameter of NH₃ is smaller than that of H₂. At high temperatures, there was no effect of NH₃ adsorption on H₂ permeation characteristics, and silica membranes were highly stable in NH₃ at 400°C (i.e., gas permeance remained unchanged). On the other hand, at 50°C NH₃ molecules adsorbed on the silica improved NH₃‐permselectivity by blocking permeation of H₂ molecules without decreasing NH₃ permeance. The maximal NH₃/H₂ permeance ratio obtained during binary component separation was ～30 with an NH₃ permeance of ～10^?7 mol m^?2 s^?1 Pa^?1 at an H₂ permeation activation energy of ～6 kJ mol^?1. © 2009 American Institute of Chemical Engineers AIChE J, 2010     

Highly enhanced ammonia decomposition in a bimodal catalytic membrane reactor for COx-free hydrogen production

Ammonia decomposition in a bimodal catalytic membrane reactor (BCMR) consisting of a Ru/γ-Al₂O₃/α-Al₂O₃ bimodal catalytic support and a hydrogen-selective silica membrane in a single unit was proposed for CO_x-free hydrogen production in the present study. The bimodal catalytic membrane showed a H₂ permeance of 6.2 × 10^-7 mol/(m² s Pa) at 500 °C, with H₂/NH₃ and H₂/N₂ permeance ratios of 200 and 720, respectively. Ammonia conversion was surprisingly enhanced form 45 to 95% at 450 °C in the BCMR after selective H₂ extraction. The BCMR showed excellent stability with respect to both gas permeation properties and catalytic activities.     

Stable equilibrium shift of methane steam reforming in membrane reactors with hydrogen‐selective silica membranes

Equilibrium shifts of methane steam reforming in membrane reactors consisting of either tetramethoxysilane‐derived amorphous hydrogen‐selective silica membrane and rhodium catalysts, or hexamethyldisiloxane‐derived membrane and nickel catalysts is experimentally demonstrated. The hexamethyldisiloxane‐derived silica membrane showed stable permeance as high as 8 × 10^?8 mol m^?2 s^?1 Pa^?1 of H₂ after exposure to 76 kPa of vapor pressure at 773 K for 60 h, which was a much better performance than that from the tetramethoxysilane‐derived silica membrane. Furthermore, the better silica membrane also maintained selectivity of H₂/N₂ as high as 10³ under the above hydrothermal conditions. The degree of the equilibrium shifts under various feedrate and pressure conditions coincided with the order of H₂ permeance. In addition, the equilibrium shift of methane steam reforming was stable for 30 h with an S/C ratio of 2.5 at 773 K using a membrane reactor integrated with hexamethyldisiloxane‐derived membrane and nickel catalyst. © 2010 American Institute of Chemical Engineers AIChE J, 2011     

Permeation properties of hydrogen and water vapor through porous silica membranes at high temperatures

Silica and cobalt‐doped silica membranes that showed a high permeance of 1.8 × 10^?7 mol m^?2 s^?1 Pa^?1 and a H₂/N₂ permeance ratio of ～730, with excellent hydrothermal stability under steam pressure of 300 kPa, were successfully prepared. The permeation mechanism of gas molecules, focusing particularly on hydrogen and water vapor, was investigated in the 300–500°C range and is discussed based on the activation energy of permeation and the selectivity of gaseous molecules. The activation energy of H₂ permeation correlated well with the permeance ratio of He/H₂ for porous silica membranes prepared by sol–gel processing, chemical vapor deposition (CVD), and vitreous glasses, indicating that similar amorphous silica network structures were formed. The permeance ratios of H₂/H₂O were found to range from 5 to 40, that is, hydrogen (kinetic diameter: 0.289 nm) was always more permeable than water (0.265 nm). © 2010 American Institute of Chemical Engineers AIChE J, 2011     

Hydrogen generation and purification in a composite Pd hollow fiber membrane reactor: Experiments and modeling

“Pd nanopore” composite membranes are a novel class of H₂ permselective membranes in which a thin layer of Pd is grown within the pores of a supported nanoporous layer. In this work, Pd nanopore membranes and conventional Pd top-layer membranes were used in the generation of high-purity H₂ from the catalytic decomposition of anhydrous NH₃. An effective 4 μm thick Pd nanopore membrane and 13 μm thick Pd top-layer membrane were synthesized on 2 mm O.D. α-Al₂O₃ hollow fibers. The permeation features of the membranes were determined and the membranes were then employed in a single fiber packed-bed membrane reactor in which Ni-catalyzed NH₃ decomposition served as the test reaction, with conditions spanning a range of conditions (500–600 °C; 3–5 bar total retentate pressure; 60–1200 scc/h g cat space velocity). The NH₃ conversions in both the PBMRs were approximately 10% higher than in a packed-bed reactor (PBR) under similar conditions. The increase in conversion with the PBMR was attributed to the removal of H₂, which has an inhibitory effect on the forward kinetics of the reaction as per the Temkin-Pyzhev type rate mechanism. Reactor productivities in the range of 2 mol/s m³ (at 85% H₂ utilization) to 7 mol/s m³ (at 50% H₂ utilization) were obtained. The permeate stream purity exceeded 99.2% H₂. A two-dimensional pseudo-homogeneous model was successfully used to simulate the experimental results and to interpret the findings. Permeation and kinetic parameters were estimated in permeation and PBR experiments, respectively. Without any data fitting the PBMR model predictions demonstrated very good agreement with experimental trends. Together with an analysis of the characteristic times, the model determined that transverse transport of hydrogen in the catalyst bed limited PBMR performance. The model was used to determine the rate limiting step and to suggest ways in which the reactor productivities could be further improved.     

Evaluation and fabrication of pore‐size‐tuned silica membranes with tetraethoxydimethyl disiloxane for gas separation

Organic/inorganic hybrid silica membranes were prepared from 1,1,3,3‐tetraethoxy‐1,3‐dimethyl disiloxane (TEDMDS) by the sol‐gel technique with firing at 300–550°C in N₂. TEDMDS‐derived silica membranes showed high H₂ permeance (0.3–1.1 × 10^?6 mol m^?2 s^?1 Pa^?1) with low H₂/N₂ (～10) and high H₂/SF₆ (～1200) perm‐selectivity, confirming successful tuning of micropore sizes larger than TEOS‐derived silica membranes. TEDMDS‐derived silica membranes prepared at 550°C in N₂ increased gas permeances as well as pore sizes after air exposure at 450°C. TEDMDS had an advantage in tuning pore size by the “template” and “spacer” techniques, due to the pyrolysis of methyl groups in air and Si? O? Si bonding, respectively. For pore size evaluation of microporous membranes, normalized Knudsen‐based permeance, which was proposed based on the gas translation model and verified with permeance of zeolite membranes, reveals that pore sizes of TEDMDS membranes were successfully tuned in the range of 0.6–1.0 nm. © 2011 American Institute of Chemical Engineers AIChE J, 2011     

Carbon dioxide separation and dry reforming of methane for synthesis of syngas by a dual‐phase membrane reactor

High‐temperature CO₂ selective membranes offer potential for use to separate flue gas and produce a warm, pure CO₂ stream as a chemical feedstock. The coupling of separation of CO₂ by a ceramic–carbonate dual‐phase membrane with dry reforming of CH₄ to produce syngas is reported. CO₂ permeation and the dry reforming reaction performance of the membrane reactor were experimentally studied with a CO₂–N₂ mixture as the feed and CH₄ as the sweep gas passing through either an empty permeation chamber or one that was packed with a solid catalyst. CO₂ permeation flux through the membrane matches the rate of dry reforming of methane using a 10% Ni/γ‐alumina catalyst at temperatures above 750°C. At 850°C under the reaction conditions, the membrane reactor gives a CO₂ permeation flux of 0.17 mL min^?1 cm^?2, hydrogen production rate of 0.3 mL min^?1 cm^?2 with a H₂ to CO formation ratio of about 1, and conversion of CO₂ and CH₄, respectively, of 88.5 and 8.1%. © 2013 American Institute of Chemical Engineers AIChE J, 59: 2207–2218, 2013     

Theoretical investigation of a water‐gas‐shift catalytic membrane for diesel reformate purification

The novel application of a catalytic water‐gas‐shift membrane reactor for selective removal of CO from H₂‐rich reformate mixtures for achieving gas purification solely via manipulation of reaction and diffusion phenomena, assuming Knudsen diffusion regime and the absence of hydrogen permselective materials, is described. An isothermal, two‐dimensional model is developed to describe a tube‐and‐shell membrane reactor supplied with a typical reformate mixture (9% CO, 3% CO₂, 28% H₂, and 15% H₂O) to the retentate volume and steam supplied to the permeate volume such that the overall H₂O:CO ratio within the system is 9:1. Simulations indicate that apparent CO:H₂ selectivities of 90:1 to >200:1 at H₂ recoveries of 20% to upwards of 40% may be achieved through appropriate design of the catalytic membrane and selection of operating conditions. Under these conditions, simulations predict an apparent hydrogen permeability of 2.3 × 10^?10 mol m^?1 Pa, which compares favorably against that of competing hydrogen‐permselective membranes. © 2013 American Institute of Chemical Engineers AIChE J, 59: 4334–4345, 2013     

Pure H2 production through hollow fiber hydrogen‐selective MFI zeolite membranes using steam as sweep gas

Hollow fiber MFI zeolite membranes were modified by catalytic cracking deposition of methyldiethoxysilane to enhance their H₂/CO₂ separation performance and further used in high temperature water gas shift membrane reactor. Steam was used as the sweep gas in the MR for the production of pure H₂. Extensive investigations were conducted on MR performance by variations of temperature, feed pressure, sweep steam flow rate, and steam‐to‐CO ratio. CO conversion was obviously enhanced in the MR as compared with conventional packed‐bed reactor (PBR) due to the coupled effects of H₂ removal as well as counter‐diffusion of sweep steam. Significant increment in CO conversion for MR vs. PBR was obtained at relatively low temperature and steam‐to‐CO ratio. A high H₂ permeate purity of 98.2% could be achieved in the MR swept by steam. Moreover, the MR exhibited an excellent long‐term operating stability for 100 h in despite of the membrane quality. © 2015 American Institute of Chemical Engineers AIChE J, 61: 3459–3469, 2015     

Upgrading of Simulated Syngas by Using a Nanoporous Silica Membrane Reactor

The permeance properties of a nanoporous silica membrane were first evaluated in a laboratory‐scale porous silica membrane reactor (MR). The results indicated that CO, CO₂, and N₂ inhibited H₂ permeation. Increased H₂ permeability and selectivity were obtained when gas was transferred from the lumen side to the shell side. This was therefore selected as a suitable permeation direction. On this basis, upgrading of simulated syngas was experimentally investigated as a function of temperature (150 – 300 °C), feed pressure (up to 0.4 MPa), and gas hourly space velocity (GHSV), by using a nanoporous silica MR in the presence of a Cu/ZnO/Al₂O₃ catalyst. The CO conversion obtained with the MR was significantly higher than that with a packed‐bed reactor (PBR) and broke the thermodynamic equilibrium of a PBR at 275 – 300 °C and a GHSV of 2665 h^–1. The use of a low GHSV and high feed pressure improved the CO conversion and led to the recovery of more H₂.     

Hybrid H2-Selective Silica Membranes Prepared by Chemical Vapor Deposition

Hybrid organic-inorganic H₂-selective membranes consisting of single-layer or dual-layers of silica incorporating aromatic groups are deposited on a porous alumina support by chemical vapor deposition (CVD) in an inert atmosphere at high temperature. The single-layer silica membranes, which are made by the simultaneous decomposition of phenyltriethoxysilane (PTES) and tetraethylorthosilicate (TEOS), have good hydrothermal stability at high temperature and a high permeance for hydrogen in the order of 10^?7 mol m^?2 s^?1 Pa^?1 at 873 K, while preventing the passage of other larger molecular gases such as CH₄ and CO₂. The dual-layer silica membranes, which are obtained from the sequential decomposition of PTES and TEOS, exhibit an extremely high permeance for hydrogen of 3.6 × 10^?6 mol m^?2 s^?1 Pa^?1 at 873 K with a permselectivity of hydrogen over methane of 30. A normalized Knudsen based permeance method is applied to measure the pore size of PTES-derived silica membrane on the dual-layer silica membrane before treatment with TEOS. The method indicates that the pore size of the silica network is approximately in the range of 0.50–0.85 nm, which is higher than the characteristic length of pure silica membranes of 0.3 nm, accounting for the high permeance of the hybrid membranes.     

A robust mixed‐conducting multichannel hollow fiber membrane reactor

To accelerate the commercial application of mixed‐conducting membrane reactor for catalytic reaction processes, a robust mixed‐conducting multichannel hollow fiber (MCMHF) membrane reactor was constructed and characterized in this work. The MCMHF membrane based on reduction‐tolerant and CO₂‐stable SrFe_0.8Nb_0.2O_3‐δ (SFN) oxide not only possesses a good mechanical strength but also has a high oxygen permeation flux under air/He gradient, which is about four times that of SFN disk membrane. When partial oxidation of methane (POM) was performed in the MCMHF membrane reactor, excellent reaction performance (oxygen flux of 19.2 mL min^?1 cm^?2, hydrogen production rate of 54.7 mL min^?1 cm^?2, methane conversion of 94.6% and the CO selectivity of 99%) was achieved at 1173 K. And also, the MCMHF membrane reactor for POM reaction was operated stably for 120 h without obvious degradation of reaction performance. © 2015 American Institute of Chemical Engineers AIChE J, 61: 2592–2599, 2015     

Control of H2S waste gas emissions with a biological activated carbon filter

The removal of high concentrations of H₂S from waste gases containing mixtures of H₂S and NH₃ was studied using the pilot‐scale biofilter. Granular activated carbon (GAC), selected as support material in this study, demonstrated its high adsorption capacity for H₂S and good gas distribution. Extensive tests to determine removal characteristics, removal efficiency, and removal capacity of high H₂S levels and coexisting NH₃ in the system were performed. In seeking the appropriate operating conditions, the response surface methodology (RSM) was employed. H₂S removal capacities were evaluated by the inoculated bacteria (biological conversion) and BDST (Bed Depth Service Time) methods (physical adsorption). An average 98% removal efficiency for 0.083–0.167 mg dm^?3 of H₂S and 0.004–0.021 mg dm^?3 of NH₃ gases was achieved during the operational period because of rapid physical adsorption by GAC and subsequently an effective biological regeneration of GAC by inoculated Pseudomonas putida CH11 and Arthrobacter oxydans CH8. The results showed that H₂S removal efficiency for the system was not affected by inlet NH₃ concentrations. In addition, no acidification was observed in the BAC biofilter. High buffer capacity and low moisture demand were also advantages of this system. The maximal inlet loading and critical loading for the system were 18.9 and 7.7 g‐H₂S m^?3 h^?1, respectively. The results of this study could be used as a guide for the further design and operation of industrial‐scale systems. Copyright © 2004 Society of Chemical Industry     

A nonenzymatic hydrogen peroxide sensor based on Pt/PPy hollow hybrid microspheres

The surface of silica particles was NH₂? functionalized by 3‐aminopropyltrimethoxysilane, then the platinum/polypyrrole hybrid hollow microspheres were prepared by treating the SiO₂ template decorated by the H₂PtCl₆ via the NH₂? group with pyrrole vapor and developed as hydrogen peroxide (H₂O₂) sensor. The platinum/polypyrrole hybrid hollow sphere materials were characterized by transmission electron microscopy and infrared spectroscopy, and the catalytic electrodes were investigated by electrochemical method. The results showed that the nonenzymatic sensor displayed a good electro‐catalytic response and high sensitivity to the oxidation of H₂O₂, and the resulting sensor showed a wide linear range from 1.9 to 9.7 mM H₂O₂. The obvious response could be still observed in i–t curve when the concentration of H₂O₂ was as low as 1.0 μM. © 2012 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

High‐rate hydrogen separation using an MIEC oxygen permeable membrane reactor

In this study, we propose using mixed ionic‐electronic conducting (MIEC) oxygen permeable membrane to separate hydrogen via the water splitting reaction. To do that, steam was fed to one side of the membrane (side I) and a low‐purity hydrogen was fed to the other side (side II). Oxygen from water splitting on side I permeates through the membrane driven by an oxygen chemical potential gradient across the membrane to react with the low‐purity hydrogen on side II. After condensation and drying, high‐purity hydrogen is acquired from side I. Thus, the hydrogen separation process is realized based on the fact that the low‐purity hydrogen is consumed and high‐purity hydrogen is acquired. We achieved a high hydrogen separation rate (13.5 mL cm^?2 min^?1) at 950°C in a reactor equipped with a 0.5‐mm‐thick Ba_0.98Ce_0.05Fe_0.95O_3‐δ membrane. This research proofed that it is feasible to upgrade hydrogen purity using an MIEC oxygen permeable membrane. © 2016 American Institute of Chemical Engineers AIChE J, 63: 1278–1286, 2017     

Development of an All-ceramic Module with Silica Membrane Tubes for High Temperature Hydrogen Separation

Abstract

Heat resistant hydrogen selective membranes are desired for use as membrane reactors in low-temperature hydrogen production via the steam reforming of hydrocarbons, which are usually operated over 1000 K. In addition, developing a multi-tubular type of membrane unit that can process more reactants is becoming more and more important in order to realize the practical use of membrane reactors.

In this study, an all-ceramic module consisting of 6 silica membrane tubes with a comparatively large membrane area of around 0.04 m² was fabricated by a counter-diffusion chemical vapor deposition technique. As a result, the H₂/N₂ ideal separation factor and the H₂ permeance of the module were 1300 and 1.9 × 10^?7 mol·m^?2s^?1Pa^?1 at 873 K, respectively. In a 1000-hour thermal stability test for the silica membrane module, it was found that the H₂ permeance initially decreased by about 30% and then became steady under ΔP = 0.95 MPa at 773 K.     

Design and operational considerations of catalytic membrane reactors for ammonia synthesis

Production of ammonia using hydrogen derived from renewable electricity instead of hydrocarbon reforming would dramatically reduce the carbon footprint of this commodity chemical. Novel technologies such as catalytic membrane reactors (CMRs) may potentially be more compatible with distributed ammonia production than the conventional Haber–Bosch process. A reactor model is developed based on integrating a standard industrial iron catalyst into a CMR equipped with an inorganic membrane that is selective to NH₃ over N₂/H₂. CMR performance is studied as functions of wide ranges of membrane properties and operating conditions. Conversion and ammonia recovery are dictated principally by the ammonia permeance, and the benefits by using membranes become significant above 100 GPU = 3.4 × 10⁻⁸ mol m⁻² s⁻¹ Pa⁻¹. To be effective, the CMR requires a minimum selectivity for ammonia of 10 over both nitrogen and hydrogen and purity scales with the effective selectivity. Increasing the pressure of operation significantly improves all metrics, and at P = 30 bar with a quality membrane, ammonia is almost completely recovered, enabling direct recycle of unreacted hydrogen and nitrogen without need for recompression. Temperature drives conversion and scales monotonically without thermodynamic limitations in a CMR. Alternatively, the temperature may be reduced as low as 300°C while achieving conversion levels surpassing equilibrium limits at T = 400°C in a conventional reactor.     

High-performance oxygen transport membrane reactors integrated with IGCC for carbon capture

Precombustion carbon capture is an effective strategy to reduce large-scale CO₂ emissions, which is mainly used in the area of integrated gasification combined cycle (IGCC) power plants. Oxygen transport membranes (OTMs) were suggested as the air separation unit to produce high purity oxygen for the gasifier. However, the improvement in efficiency was limited. Here, a new IGCC process is reported based on a robust OTM reactor, where the OTM reactor is used behind the coal gasifier. This IGCC-OTM process fulfills syngas oxidation, H₂ production, and carbon capture in one unit, thus a significant decrease of the energy penalty is expectable. The membrane reactor does not use noble metal components, and exhibits high hydrogen production rates, high hydrogen separation factor (10³–10⁴), and stable performance in a gas mixture mimicking real syngas compositions from a coal gasifier with H₂S concentrations up to 1,000 ppm.     

Dual-phase membrane reactor for hydrogen separation with high tolerance to CO2 and H2S impurities

Catalytic membrane reactors based on oxygen-permeable membranes are recently studied for hydrogen separation because their hydrogen separation rates and separation factors are comparable to those of Pd-based membranes. New membrane materials with high performance and good tolerance to CO₂ and H₂S impurities are highly desired. In this work, a new membrane material Ce_0.85Sm_0.15O_1.925–Sr₂Fe_1.5Mo_0.5O_6-δ (SDC–SFM) was prepared for hydrogen separation. It exhibits high conductivities at low oxygen partial pressures, which is benefit to electron transfer and ion diffusion. A high hydrogen separation rate of 6.6 mL cm⁻² min⁻¹ was obtained on a 0.5-mm-thick membrane coated with Ni/SDC catalyst at 900°C. The membrane reactor was operated steadily for 532 h under atmospheres containing CO₂ and H₂S impurities. Various characterizations reveal that SDC–SFM has good stability in the membrane reactor for hydrogen separation. All facts confirm that SDC–SFM is promising for hydrogen separation in practical applications. © 2018 American Institute of Chemical Engineers AIChE J, 65: 1088–1096, 2019