REACTOR-MEMBRANE PERMEATOR CASCADE FOR ENHANCED PRODUCTION AND RECOVERY OF H2 AND CO2 FROM THE CATALYTIC METHANE-STEAM REFORMING REACTION

The catalytic reforming of methane by steam is an important industrial process that produces H₂, CO and CO₂, thus chemically transforming natural gas, coal gas and light hydrocarbon feedstocks to synthesis gas or hydrogen fuel. Methane-steam reforming may consist of a number of reactions depending on the reforming catalyst, operating conditions and feedstock composition, The typical industrially desirable reactions are the reverse of methanation (CH₄ + H₂O = CO + 3H₂) and the water-gas shift (CO + H₂O = CO₂ + H₂). Both reactions are equilibrium limited and the composition of the mixture that exits the reformer is in accordance with the one calculated thermodynarmically. Removal of reaction products at the reactor exit by means of selective membrane permeation can offer improved CH₄ conversions and CO₂ and H₂ yields, assuming the subsequent utilization of the reject streams by a second methane-steam reformer. We numerically investigated the feasibility of a system of two tubular methane-steam reformers, in series with an intermediate permselective polyimide membrane permeator, as means of improving the overall CH₄ conversion and the H₂, CO₂ yields over conventional methane-steam reforming equilibrium reaction-separation schemes that are currently in industrial practice. The unique feature of the permselective polyimide separator is the simultaneous removal of H₂ and CO₂ versus CH₄ and CO from the reformed streams. The utilized 6FDA-3,3', 5,5'-TMB aromatic polyimide was reportedly characterized [10] and found to exhibit superior permselective properties compared with other polyimides of the same or different dianhydride sequence. Conversion and yield of the designed reactor-membrane permeator reforming system can be maximized by optimizing the permselective properties of the membrane material and the design variables of the reactors and the permeator. Product recovery and purity in the permeate stream need to be compromised to overall enhance methane conversion and product yield. The operating variables that were varied to investigate their effect on the magnitude of conversion and yield included the inlet pressure of the first reformer, the temperature of both reformers, and the permeator dimensionless Pe' number (variation of the first two variables results to a drastic change in the composition of the reformed stream that enters into the permeator). The numerical results show that the new reformer-membrane permeator cascade process can be more effective (it can offer increased CH₄ conversions and H₂, CO₂ yields) than conventional equilibrium methane-steam reforming reaction-separation processes currently in practice.     

ALTERNATIVE GENERATION OF H2, CO AND H2, CO2 MIXTURES FROM STEAM-CARBON DIOXIDE REFORMING OF METHANE AND THE WATER GAS SHIFT WITH PERMEABLE (MEMBRANE) REACTORS

A new process is proposed which converts CO₂ and CH₄ containing gas streams to synthesis gas, a mixture of CO and H₂ via the catalytic reaction scheme of steam-carbon dioxide reforming of methane or the respective one of only carbon dioxide reforming of methane, in permeable (membrane) reactors. The membrane reformer (permreactor) can be made by reactive or inert materials such as metal alloys, microporous ceramics, glasses and composites which all are hydrogen permselective. The rejected CO reacts with steam and converted catalytically to CO₂ and H₂ via the water gas shift in a consecutive permreactor made by similar to the reformer materials and alternatively by high glass transition temperature polymers. Both permreactors can recover H₂ in permeate by using metal membranes, and H₂ rich mixtures by using ceramic, glass and composite type permselective membranes. H₂ and CO₂ can be recovered simultaneously in water gas shift step after steam condensation by using organic polymer membranes. Product yields are increased through permreactor equilibrium shift and reaction separation process integration.

CO and H₂ can be combined in first step to be used for chemical synthesis or as fuel in power generation cycles. Mixtures of CO₂ and H₂ in second step can be used for synthesis as well (e.g., alternative methanol synthesis) and as direct feed in molten carbonate fuel cells. Pure H₂ from the above processes can be used also for synthesis or as fuel in power systems and fuel cells. The overall process can be considered environmentally benign because it offers an in-situ abatement of the greenhouse CO₂ and CH₄ gases and related hydrocarbon-CO₂ feedstocks (e.g., coal, landfill, natural, flue gases), through chemical reactions, to the upgraded calorific value synthesis gas and H₂, H₂ mixture products.     

褐煤热解-气化-制油系统的CO2减排策略

褐煤热解-气化-制油系统是现代煤化工发展的一个重要研究内容。来自系统多个单元产生的CH₄和CO₂如果发生重整反应,将重整得到H₂/CO比值较高的合成气添加到制油流程中,可实现更多的C被固定到产品中而减少CO₂的直接排放量。对CH₄-CO₂和CH₄-H₂O两种重整反应方式、来自煤热解和费托合成两股甲烷气和典型的干粉气化和水煤浆气化两种流程进行了组合研究。分析结果显示,来自热解和费托合成的甲烷重整后不足以提供调节合成气H₂/CO比例所需的氢气,水煤气变换反应对于褐煤制油系统来说是必需的。从C转化成油的角度来看,采用干粉气化和CH₄-H₂O重整的方案是较好的选择。     

Tri-reforming of methane: a novel concept for catalytic production of industrially useful synthesis gas with desired H2/CO ratios

A novel process concept called tri-reforming of methane has been proposed in our laboratory using CO₂ in the flue gases from fossil fuel-based power plants without CO₂ separation [C. Song, Chemical Innovation 31 (2001) 21–26]. The proposed tri-reforming process is a synergetic combination of CO₂ reforming, steam reforming, and partial oxidation of methane in a single reactor for effective production of industrially useful synthesis gas (syngas). Both experimental testing and computational analysis show that tri-reforming can not only produce synthesis gas (CO + H₂) with desired H₂/CO ratios (1.5–2.0), but also could eliminate carbon formation which is usually a serious problem in the CO₂ reforming of methane. These two advantages have been demonstrated by tri-reforming of CH₄ in a fixed-bed flow reactor at 850 °C with supported nickel catalysts. Over 95% CH₄ conversion and about 80% CO₂ conversion can be achieved in tri-reforming over Ni catalysts supported on an oxide substrate. The type and nature of catalysts have a significant impact on CO₂ conversion in the presence of H₂O and O₂ in tri-reforming in the temperature range of 700–850 °C. Among all the catalysts tested for tri-reforming, their ability to enhance the conversion of CO₂ follows the order of Ni/MgO > Ni/MgO/CeZrO > Ni/CeO₂ ≈ Ni/ZrO₂ ≈ Ni/Al₂O₃ > Ni/CeZrO. The higher CO₂ conversion over Ni/MgO and Ni/MgO/CeZrO in tri-reforming may be related to the interaction of CO₂ with MgO and more interface between Ni and MgO resulting from the formation of NiO/MgO solid solution. Results of catalytic performance tests over Ni/MgO/CeZrO catalysts at 850 °C and 1 atm with different feed compositions confirm the predicted equilibrium conversions based on the thermodynamic analysis for tri-reforming of methane. Kinetics of tri-reforming were also examined. The reaction orders with respect to partial pressures of CO₂ and H₂O are different over Ni/MgO, Ni/MgO/CeZrO, and Ni/Al₂O₃ catalysts for tri-reforming.     

化学链干重整联合制氢热力学分析及实验

提出了一种化学链甲烷干重整联合制氢工艺。该工艺由还原反应器、干重整反应器、蒸汽反应器和空气反应器组成，在实现制氢的同时获得可变H₂/CO比的合成气。借助ASPEN plus软件和小型流化床实验台，在等温条件下，温度900℃，采用Fe₂O₃/Al₂O₃载氧体，对该工艺进行热力学分析和实验验证。结果显示，当铁氧化物被还原至FeO/Fe时，干重整反应器内甲烷转化率可以达到98%，CO产率可以达到94%。干重整反应器中同时发生甲烷干重整和部分氧化反应，载氧体内部晶格氧可以有效降低积炭并提高合成气H₂/CO比。积炭发生于晶格氧消耗殆尽时。积炭进入蒸汽反应器，发生气化反应，降低氢气纯度。     

Tri-reforming of CH4 using CO2 for production of synthesis gas to dimethyl ether

In general, there are three processes for production of synthesis gas; steam reforming, CO₂ reforming and partial oxidation of methane or natural gas. In the present work, we refer to tri-reforming of methane to synthesize syngas with desirable H₂/CO ratios by simultaneous oxy-CO₂-steam reforming of methane. In this study, we report the results obtained on tri-reforming of methane over the Ni/ZrO₂ based catalyst in order to restrain the carbon deposition and to evaluate the catalytic performance. Results of tri-reforming of CH₄ by three catalysts (Ni/Ce–ZrO₂, Ni/ZrO₂ and Haldor Topsoe R67-7H) are showed that the coke on the reactor wall and the surface of catalyst were reduced dramatically. It was found that the weak acidic site, basic site and redox ability of Ce–ZrO₂ play an important role in tri-reforming of methane conversion. Carbon deposition depends not only on the nature of support, but also on the oxidant as like steam or oxygen. Therefore, the process optimization by reactant ratios is important to manufacture the synthesis gas from natural gas and carbon dioxide.     

Electrocatalytic reforming of carbon dioxide by methane in SOFC system

The reaction of carbon dioxide catalytic reforming with methane is an attractive route because these greenhouse gases can be converted into variable feedstocks. However this reaction is a highly energy consuming and coke forming process. These problems were improved by the electrocatalytic reforming of CO₂ with CH₄ in a solid oxide fuel cell (SOFC) membrane reactor system, which generates high electrical power and synthesis gases. The single cell consists of catalyst electrode (NiO–MgO), counter electrode ((La,Sr)MnO₃) and Y₂O₃ stabilized ZrO₂ (YSZ) electrolyte. The reaction rates of CO₂ and CH₄, and the electrochemical properties were investigated by an on-line GC and impedance-analyzer under open- and closed-circuit conditions, respectively. It was found that reaction rates of CO₂ and CH₄ under the closed-circuit condition were more stable than those of the open-circuit. The results were interpreted that the stability of catalyst anode was maintained by the reaction of oxygen ion transferred from the cathode with the surface carbon formed in the internal CO₂ reforming by CH₄ in SOFC system.     

Intensification of low-grade methane enrichment in nitrogen mixture by CH4/CO2 displacement

To solve the problem of CO₂ uncompleted desorption in the process of CO₂ displacement enhancing the adsorption separation of CH₄/N₂, a small amount of product gas CH₄ was used as purge gas to improve the CO₂ desorption. CH₄/CO₂ mixture gas obtained from desorption step was recycled as the displacement gas to enhance the enrichment of low-grade methane in nitrogen mixture. In this work, the research conducted the experiments for CH₄/N₂ separation using CH₄/CO₂ displacement intensification adsorption and the laboratory-made coconut shell activated carbon as sorbent. The mathematical models were built in gPROMS and the accuracy of models was verified by comparison of simulations and CH₄/N₂/CO₂ breakthrough experiments. The performance of enrichment of low-grade methane with displacement intensification using different displacer was compared. The result showed that the process with CH₄/CO₂ displacement had higher purity product than CO₂ displacement. The CH₄/ CO₂ mixed gas replacement enhanced vacuum pressure swing adsorption cycle experiment was carried out, which can jointly enrich 14% CH₄/ N₂ and 53% CH₄/CO₂ to 98.8%, and at the same time obtain a recovery rate of 77.8%.     

CH4/CO2混合气置换强化含氮低品质甲烷的浓缩

针对CO₂置换吸附分离CH₄/N₂过程中CO₂再生困难的问题,采用少量产品气CH₄真空吹扫以提高CO₂的解吸效果,并以解吸得到的CH₄/CO₂混合气为置换步骤的置换气,通过置换来强化含氮低品质甲烷的浓缩过程。以自制椰壳活性炭为吸附剂,对CH₄/CO₂混合气置换强化吸附回收含氮低品质甲烷工艺过程进行了实验与模拟研究。在gPROMS软件中建立并求解固定床吸附分离模型方程,预测了CH₄、N₂ 和CO₂在自制椰壳活性炭上的竞争吸附穿透曲线,通过预测结果和实验的对比,验证了数学模型方程的准确性。对比了不同置换气强化吸附分离低品质甲烷的效果,结果表明CH₄/CO₂混合气置换强化相对于CO₂置换强化可获得更高纯度产品。进行了CH₄/CO₂混合气置换强化真空变压吸附循环实验,可以将14%的CH₄/N₂和53%的CH₄/CO₂联合富集到98.8%,同时获得77.8%的回收率。     

Study of mixed steam and CO2 reforming of CH4 to syngas on MgO-supported metals

The activity of mixed steam and CO₂ reforming of CH₄ to produce synthesis gas was investigated and compared with those of steam reforming alone and CO₂ reforming alone at 600–900°C under atmosphere pressure on MgO-supported noble metals. Mixed reforming shows a far lower CH₄ conversion than the value for thermodynamic equilibrium. The activity decreases following the order Ru,Rh> Ir> Pt,Pd. Little deactivation was observed for Ru, Rh and Ir catalysts. An isotope labelled ¹³CO₂ experiment was carried out in situ for mixed reforming on Rh/MgO and the results suggest that CO₂ dissociates as CO-M and O-M. The results of the temperature program reaction (TPR) of mixed reforming shows that CH₄ adsorbs and dissociates before reaction starts and that CO₂ reforming and steam reforming start simultaneously. A possible reaction mechanism is discussed.     

Roles of CO2 and H2O as oxidants in the plasma reforming of aliphatic hydrocarbons

Roles of CO₂ and H₂O as oxidants are discussed based on the data on the substrate conversions and the product distributions in the nonthermal plasma reforming of aliphatic hydrocarbons such as methane, propane, and neopentane from 303 K to 433 K. Only small effects of initial concentrations of hydrocarbons and types of oxidants are observed on hydrocarbon conversions, and the initial chemical interaction between hydrocarbons and the oxidants unlikely occurs. CO₂ and H₂O have shown the comparable oxidation powers in the hydrocarbon reforming. Two molar excess of CO₂ or H₂O to methane is required to oxidize methane carbon atoms to CO and CO₂, and larger amounts of CO₂ or H₂O for propane and neopentane. The different natures of CO₂ and H₂O are reflected in the synthesis gas composition as in the ordinary catalytic reforming processes at higher temperatures: higher H₂ yields and higher H₂ to CO ratios on addition of H₂O.     

带压环境中CO2/H2O/N2气体稀释对合成气层流火焰速度的影响

合成气稀释燃烧是燃气轮机高效低污染燃烧的重要运行方式。本文以CO₂、H₂O和N₂为稀释气体,利用数值模拟方法研究稀释比对不同压力下合成气（CO/H₂/CH₄）层流火焰速度（S_L）的影响规律,并从自由基浓度变化、敏感性数值和生成速率（rate of production,ROP）三个方面解析三种气体的物理和化学作用机理。结果表明,S_L随燃烧压力和稀释比的增大而不断减小,其中CO₂对层流火焰速度的抑制最为显著。稀释气体的物理效应对层流火焰速度的影响远大于化学效应,但CO₂和H₂O的化学效应不能忽略。化学效应则是通过改变H和OH自由基浓度影响S_L,其中CO₂稀释降低H和OH自由基浓度,H₂O稀释则是降低H自由基浓度,从而降低合成气的层流火焰速度。进一步反应动力学分析发现了H/OH浓度变化在低压、加压下的主要化学反应路径,且受H₂O稀释的化学反应速率对压力较CO₂更为敏感。     

煤和焦炉气联供制烯烃过程的建模模拟与分析

由于煤富碳少氢,煤制烯烃过程生产1 t产品将排放约5.8 t CO₂.与此同时,中国焦炭工业每年产生约7×10¹⁰ m³的副产物焦炉气,这些富氢的焦炉气大多被燃烧或直接排放进入大气,对环境造成严重影响的同时还浪费了巨大的经济价值.本文对焦炉气辅助煤制烯烃的新过程进行了建模模拟与系统分析.焦炉气与煤元素互补,焦炉气中的H₂可用来调节合成气的氢碳比;CH₄可通过甲烷水蒸气重整和甲烷干重整两个过程,提高合成气的氢碳比的同时降低煤制烯烃过程排放的CO₂,提高碳元素利用率,实现节能减排.这个新的联供过程的能效比煤制烯烃过程提高了约10个百分点,而CO₂排放量则减少了约95%.     

Ni-CeO2-K/γ-Al2O3催化剂上沼气联合重整制合成气

采用超声波辅助等体积浸渍法制备Ni-CeO₂-K/γ-Al₂O₃催化剂用于沼气联合重整反应,采用 BET、XRD、TG/DTG等技术对催化剂性质进行了表征,在微型固定床反应装置中研究了反应温度、体积空速、原料气组成等对沼气联合重整反应特性的影响,并对催化剂的稳定性进行了研究。结果表明,助剂CeO₂的加入,提高了催化剂中Ni的分散度,降低了催化剂还原温度。升高反应温度和减小体积空速,能够提高沼气中CH₄和CO₂的转化率;原料气中加入水蒸气,能够明显提高H₂/CO体积比;加入的O₂容易与H₂、CO发生反应,CH₄转化率稍有提高。在常压、反应温度850℃、体积空速为100000h^-1、摩尔比CH₄∶CO₂∶H₂O∶O₂∶Ar=1∶0.5∶0.5∶0.1∶0.01的优化条件下,沼气中CH₄转化率超过95%,CO₂转化率超过75%,生成合成气H₂/CO体积比约为1.6,反应48h后,催化剂未见积炭,保持稳定的活性。与沼气干重整相比,沼气联合重整不利于沼气中CO₂的转化。     

铁基氧载体化学链CO2重整CH4方法制备合成气

提出一种铁基氧载体（Fe₃O₄/FeO）化学链CO₂重整CH₄方法制备合成气。为评价该系统的性能,采用Aspen Plus软件对其进行过程模拟和热力学分析。以CH₄转化率、CO₂转化率、能源利用效率和产气氢碳比（H₂/CO）为评价指标,得到系统的优化运行条件,并研究各操作参数（包括各反应器的温度和压力、氧载体甲烷比和CO₂甲烷比）对系统性能的影响。结果表明：当系统处于优化工况时,得到CH₄转化率为97.91%、CO₂转化率为32.76%、能源利用效率为93.77%及产气氢碳比为0.93。该系统能有效利用CO₂和CH₄这两种温室气体获得较低氢碳比的合成气,利于二甲醚的高效合成。     

Oxidative reforming of biomass derived ethanol for hydrogen production in fuel cell applications

Oxidative reforming of biomass derived ethanol over an inexpensive Ni–Cu/SiO₂ catalyst has been carried out with respect to solid polymer fuel cell (SPFC) applications. Two types of runs were performed, either under diluted conditions (with helium as diluent) or under conditions corresponding to an on-board reformer. Selectivities of ethanol reforming have been analyzed as a function of operating parameters: reaction temperature, H₂O/EtOH molar ratio and O₂/EtOH molar ratio of the feed to the reformer. The hydrogen content and the CO₂/CO_x molar ratio in the outlet gases were used as parameters to optimize the operating conditions in the reforming reactor. The tests carried out at on-board reformer conditions evidenced that an H₂O/EtOH molar ratio=1.6 and an O₂/EtOH molar ratio=0.68 at 973 K allow a hydrogen rich mixture (33%) that can be considered of high interest for SPFC. Furthermore, the use of oxygen decreases the production of methane and coke which increases in turn the lifetime of the catalyst. The stability of this catalyst has been fully demonstrated by long time runs.     

Oxidation and reforming reactions of CH4 on a stepped Pt(5 5 7) single crystal

The oxidation and reforming kinetics of methane by O₂, CO₂ and H₂O were studied on a stepped Pt(5 5 7) single crystal from 623 to 1050 K under methane rich conditions. The rate of carbon deposition was followed by ex-situ Auger electron spectroscopy under non-oxidative conditions. The apparent activation energy for methane decomposition was significantly lower than the apparent barriers measured for both total oxidation, CO₂ and H₂O reforming. Total oxidation of methane to CO₂ and H₂O followed by combined dry and steam reforming (combined combustion-reforming) led to CO production rates which were higher than direct CO₂ or H₂O reforming rates. The enhanced rates are most likely due to the ability of adsorbed oxygen to prevent carbon nucleation and/or scavenge carbon enabling the reforming reaction to turnover on a larger fraction of sites. Comparable amounts of carbon were found by Auger electron spectroscopy measurements after both direct dry or steam reforming, while combined oxidation-reforming had considerable less carbon. During direct dry or steam reforming, CO₂ and H₂O serve only to scavenge adsorbed atomic carbon, while in the presence of oxygen, carbon is removed by both combustion and reforming routes.     

Mechanistic study of partial oxidation of methane to synthesis gas over supported rhodium and ruthenium catalysts using in situ time-resolved FTIR spectroscopy

In situ time-resolved FTIR spectroscopy was used to study the reaction mechanism of partial oxidation of methane to synthesis gas and the interaction of CH₄/O₂/He (2/1/45) gas mixture with adsorbed CO species over SiO₂ and γ-Al₂O₃ supported Rh and Ru catalysts at 500–600°C. It was found that CO is the primary product for the reaction of CH₄/O₂/He (2/1/45) gas mixture over H₂ reduced and working state Rh/SiO₂ catalyst. Direct oxidation of methane is the main pathway of synthesis gas formation over Rh/SiO₂ catalyst. CO₂ is the primary product for the reaction of CH₄/O₂/He (2/1/45) gas mixture over Ru/γ-Al₂O₃ and Ru/SiO₂ catalysts. The dominant reaction pathway of CO formation over Ru/γ-Al₂O₃ and Ru/SiO₂ catalysts is via the reforming reactions of CH₄ with CO₂ and H₂O. The effect of space velocity on the partial oxidation of methane over SiO₂ and γ-Al₂O₃ supported Rh and Ru catalysts is consistent with the above mechanisms. It is also found that consecutive oxidation of surface CO species is an important pathway of CO₂ formation during the partial oxidation of methane to synthesis gas over Rh/SiO₂ and Ru/γ-Al₂O₃ catalysts.     

面向氢气/甲烷分离分子筛膜微结构调控的研究进展

氢能具有燃烧值高、零碳排放等优势,发展氢能技术是实现“碳达峰、碳中和”战略的重要举措。当前,基于天然气和石油路线的制氢均存在将氢气从甲烷等烃分子中分离的过程。氢气/甲烷分离主要有变压吸附法、深冷精馏法以及膜分离法。分子筛膜具有精准分子筛分、高分离性能和稳定性好等优势,是低能耗分离氢气/甲烷最具发展潜力的膜材料。面向氢气/甲烷分离的应用需求,阐述了沸石分子筛膜和MOFs分子筛膜微结构调控策略、氢气/甲烷分离性能和构效关系的研究现状,分析了分子筛膜材料在氢气/甲烷分离领域的机遇和挑战。绘制了可与2008年聚合物膜Robeson上限图相比的分子筛膜性能数据图,并预测了分子筛膜在制氢分离领域经济可行的分离性能目标区域。     

机械化学法合成小尺寸MOF填料助力高性能CO2分离

利用金属-有机骨架UTSA-280具有特定刚性尺寸的一维孔道可以筛分CO₂、CH₄、N₂的特性,采用机械化学研磨法减小其颗粒尺寸,将UTSA-280掺入聚砜（PSf）中制备MOF基混合基质膜,用于天然气提纯和烟道气CO₂捕获。结果表明,在PSf中掺入UTSA-280不仅可以增加聚合物的CO₂渗透通量而且提高了气体分离选择性。当UTSA-280掺杂量为30%（质量）时,混合基质膜对CO₂/CH₄、CO₂/N₂的分离因子分别为56.39和53.17,CO₂的渗透通量为18.61 Barrer,相对于PSf纯膜,选择性分别提高了47.3%和63.5%,CO₂渗透通量提高了128.9%,打破了“trade-off”效应。该工作通过引进具有分子筛分效应的MOF填料,能够增加气体通量的同时提高混合基质膜对含CO₂气体的分离性能,对天然气的提纯以及烟道气的CO₂的捕获有重要意义。