Synthesis gas production using steam hydrogasification and steam reforming

Experimental work has been carried out on the mixed reforming reaction, i.e., simultaneous steam and CO₂ reforming of methane under a wide range of feed compositions and four different reaction temperatures from 700 °C to 850 °C using a commercial steam reforming catalyst. The experiments were conducted for a CO₂/CH₄ ratio from 0 to 2 and a steam to methane ratio from 3 to 5. The effect of CO₂/CH₄ ratio on the exit H₂/CO ratio and the conversions of the reactants indicate that the dry reforming reaction is dominant under increased carbon dioxide in the feed. Steam reforming of typical steam hydrogasification product gas consisting of CO, H₂ and CO₂ in addition to steam and methane has also been investigated. The H₂/CO ratio of the product synthesis gas varies from 4.3 to 3.7 and from 4.8 to 4.1 depending on the feed composition and reaction temperature. The CO/CO₂ ratios of the synthesis gas varied from 1.9 to 2.9 and 2.0 to 3.3. The results are compared with simulation results obtained through the Aspen Plus process simulation tool. The results demonstrate that a coupled steam hydrogasification and reforming process can generate a synthesis gas with a flexible H₂/CO ratio from carbon-containing feedstocks.     

Thermodynamic analysis of carbon dioxide reforming of methane in view of solid carbon formation

A thermodynamic equilibrium analysis on the multi-reaction system for carbon dioxide reforming of methane in view of carbon formation was performed with Aspen plus based on direct minimization of Gibbs free energy method. The effects of CO₂/CH₄ ratio (0.5-3), reaction temperature (573-1473 K) and pressure (1-25 atm) on equilibrium conversions, product compositions and solid carbon were studied. Numerical analysis revealed that the optimal working conditions for syngas production in Fischer-Tropsch synthesis were at temperatures higher than 1173 K for CO₂/CH₄ ratio being 1 at which about 4 mol of syngas (H₂/CO = 1) could be produced from 2 mol of reactants with negligible amount of carbon formation. Although temperatures above 973 K had suppressed the carbon formation, the moles of water formed increased especially at higher CO₂/CH₄ ratios (being 2 and 3). The increment could be attributed to RWGS reaction attested by the enhanced number of CO moles, declined H₂ moles and gradual increment of CO₂ conversion. The simulated reactant conversions and product distribution were compared with experimental results in the literatures to study the differences between the real behavior and thermodynamic equilibrium profile of CO₂ reforming of methane. The potential of producing decent yields of ethylene, ethane, methanol and dimethyl ether seemed to depend on active and selective catalysts. Higher pressures suppressed the effect of temperature on reactant conversion, augmented carbon deposition and decreased CO and H₂ production due to methane decomposition and CO disproportionation reactions. Analysis of oxidative CO₂ reforming of methane with equal amount of CH₄ and CO₂ revealed reactant conversions and syngas yields above 90% corresponded to the optimal operating temperature and feed ratio of 1073 K and CO₂:CH₄:O₂ = 1:1:0.1, respectively. The H₂/CO ratio was maintained at unity while water formation was minimized and solid carbon eliminated.     

Transient response of catalyst bed temperature in the pulsed reaction of partial oxidation of methane to synthesis gas over supported group VIII metal catalysts

Mechanisms of partial oxidation of methane to synthesis gas were studied using a pulsed reaction technique and temperature jump measurement. Catalyst bed temperatures were directly measured by introducing 1 and 3 ml pulses of a mixture of CH₄ and O₂ (2/1). With Ir, Pt and Ni/TiO₂ catalysts, a sudden temperature increase at the front edge of the catalyst bed was observed upon introduction of the pulse. The synthesis gas production basically proceeded via two-step paths consisting of highly exothermic complete methane oxidation to give H₂O and CO₂, followed by the endothermic reforming of methane with H₂O and CO₂. In contrast, with the Rh and Pd/TiO₂ catalysts, the temperature at the front edge of the catalyst bed decreased upon introduction of the CH₄/O₂ (2/1) pulse and a small increase in the temperature at the rear end was observed. Initially, the endothermic decomposition of CH₄ to H₂ and deposited carbon or CH_x probably took place at the front edge of the catalyst bed, after which the deposited carbon or generated CH_x species would be oxidized into CO_x. When the Ru/TiO₂ catalyst was used, a temperature increase at the front edge of the catalyst bed was observed upon introduction of the 3 ml pulse of CH₄/O₂. In contrast, the temperature drop at the front edge of the catalyst bed was observed for a 1 ml pulse of CH₄/O₂. These results seemed to exhibit two possibilities for a synthesis gas formation route over the Ru/TiO₂ catalyst. The reaction pathway of the partial oxidation of methane with group VIII metal-loaded catalysts depended strongly upon the metal species and reaction conditions.     

Temperature profiles of the monolith catalyst in CO<Subscript>2</Subscript> reforming of methane with<Emphasis Type="Italic">in-situ</Emphasis> combustion of methane and ethane

The temperature profiles in a monolith reactor were measured in CO₂ reforming of CH₄ within-situ combustion of methane and ethane in order to find out in what sequence the reactions are occurring. The reaction gas flowed both upward and downward. A hot spot was observed at low furnace temperatures, and it tended to disappear as the furnace temperature increased. This is due to natural extinguishment of the flame caused by the endothermic reforming reactions occurring. The hot spot disappeared at a lower temperature with the up-flow when compared with the down-flow. When the hot spot appears, H₂O and CO₂ are produced by complete oxidation and accordingly the steam reforming and the CO₂ reforming occur competitively in the rear part of the monolith. If the hot spot does not appear, it is considered that the partial oxidation of methane occurs predominantly over the complete oxidation, resulting in more efficient CO₂ removal.     

Heat transport limitations and reaction scheme of partial oxidation of methane to synthesis gas over supported rhodium catalysts

The partial oxidation of methane to synthesis gas over supported Rh catalysts is investigated, paying particular attention to removing heat transport limitations and identifying the reaction conditions within the kinetic-controlling regime. The results obtained suggest that the reaction follows the sequence of total oxidation to CO₂ and H₂O, followed by reforming reactions to synthesis gas.     

Analysis of hydrogen production from methane autothermal reformer with a dual catalyst-bed configuration

This paper presents a performance analysis of a dual-bed autothermal reformer for hydrogen production from methane using a non-isothermal, one dimensional reactor model. The first section of Pt/Al₂O₃ catalyst is designed for oxidation reaction, whereas the second one based on Ni/MgAl₂O₄ catalyst involves steam reforming reaction. The simulation results show that the dual-bed autothermal reactor provides higher reactor temperature and methane conversion compared with a conventional fixed-bed reformer. The H₂O/CH₄ and O₂/CH₄ feed ratios affect the methane conversion and the H₂/CO product ratio. The addition of steam at lower temperatures to the steam reforming section of the dual-bed reactor can produce the synthesis gas with a higher H₂/CO product ratio.     

Effect of support on the conversion of methane to synthesis gas over supported iridium catalysts

A partial oxidation of methane was carried out using iridium catalysts supported on several metal oxides. The productivity of the synthesis gas from methane was strongly affected by the choice of support oxides for the catalysts. The synthesis gas production proceeded basically via a two-step reaction consisting of methane combustion to give H₂O and CO₂, followed by the reforming of methane from CO₂ and steam. Although the combustion and the reforming of methane from steam did not depend upon the catalyst support, a large variation in the catalytic activity for the reforming of methane from CO₂ was observed over Ir catalysts with different supports. The support activity order in the reforming of methane from CO₂ with iridium catalysts was as follows: TiO₂≧ZrO₂≧Y₂O₃>La₂O₃>MgO≧Al₂O₃>SiO₂. The same order was observed in the synthesis gas production from the partial oxidation of methane. This revised version was published online in August 2006 with corrections to the Cover Date.     

CO2 conversion through combined steam and CO2 reforming of methane reactions over Ni and Co catalysts

Ni‐Co bimetallic and Ni or Co monometallic catalysts prepared for CO₂ reforming of methane were tested with the stimulated biogas containing steam, CO₂, CH₄, H₂, and CO. A mix of the prepared CO₂ reforming catalyst and a commercial steam reforming catalyst was used in hopes of maximizing the CO₂ conversion. Both CO₂ reforming and steam reforming of CH₄ occurred over the prepared Ni‐Co bimetallic and Ni or Co monometallic catalysts when the feed contained steam. However, CO₂ reforming did not occur on the commercial steam reforming catalyst. There was a critical steam content limit above which the catalyst facilitated no more CO₂ conversion but net CO₂ production for steam reforming and water‐gas shift became the dominant reactions in the system. The Ni‐Co bimetallic catalyst can convert more than 70% of CO₂ in a biogas feed that contains ~33 mol% of CH₄, 21.5 mol% of CO₂, 12 mol% of H₂O, 3.5 mol% of H₂, and 30 mol% of N₂. The H₂/CO ratio of the produced syngas was in the range of 1.8‐2. X‐ray absorption spectroscopy of the spent catalysts revealed that the metallic sites of Ni‐Co bimetallic, Ni and Co monometallic catalysts after the steam reforming of methane reaction with equimolar feed (CH₄:H₂O:N₂ = 1:1:1) experienced severe oxidation, which led to the catalytic deactivation.     

Partial Oxidation of Methane to Synthesis Gas Over Ru-Loaded Y2O3 Catalyst

Ru-loaded Y₂O₃ catalyst was investigated for the partial oxidation of methane to synthesis gas. Ru(0.5 wt%)/Y₂O₃ catalyst afforded a high CH₄ conversion of 27% at a CH₄:O₂ ratio of 5 to give nearly a 1:2 ratio of CO and H₂ with a selectivity of 75% at 873 K. Ru(0.5 wt%)/Y₂O₃ catalyst maintained high catalytic activity over 10 h in the partial oxidation of methane. Carbon deposition of the catalyst surface in the reaction of CH₄ was examined by thermogravimetric analyses, and it was found that no carbon deposition occurred on the Ru(0.5 wt%)/Y₂O₃ catalyst. The synthesis-gas production proceeded basically via a two-step reaction consisting of methane combustion to give H₂O and CO₂, followed by the reforming of methane from CO₂ and steam.     

CO2 reforming and partial oxidation of methane

CO₂ reforming and partial oxidation of CH₄ were investigated on different supported noble metal and Ni catalysts. A detailed thermodynamic analysis was performed for both reactions. The observed reaction behaviour can be predicted by thermodynamics. Product selectivity is catalyst independent, the role of the catalyst is to bring the reactants to approach equilibrium. The partial oxidation is a two-stage process, total oxidation of CH₄ is followed by CO₂ and H₂O reforming of the remaining CH₄. A staged addition of O₂ to the reactor is tested and recommended. TPSR show that the catalyst surface for CO₂ reforming was highly covered with carbonaceous species of four different types; two were identified as reactive intermediates.     

Modeling spatially resolved data of methane catalytic partial oxidation on Rh foam catalyst at different inlet compositions and flowrates

Spatially resolved species and temperature profiles measured for a wide range of inlet stoichiometries and flowrates are compared with microkinetic numerical simulations to investigate the effect of transport phenomena on the catalytic partial oxidation of methane on Rh foam catalysts. In agreement with the experimental data, the species profiles calculated at different C/O inlet stoichiometries show that both partial oxidation products (H₂, CO) and total oxidation products (H₂O, CO₂) are formed in the presence of oxygen. At the leaner stoichiometries, both oxygen and methane react in the diffusive regime at the catalyst entrance. At the richest methane stoichiometry (high C/O), surface temperatures are lower and methane consumption is only partly determined by transport. For all stoichiometries, a kinetically controlled regime prevails in the downstream reforming zone after O₂ is fully consumed. The effect of increasing the flowrate shifts all species profiles downstream and also slightly modifies the shapes of the axial profiles, due to the different effectiveness of heat and mass transfer. Despite enhanced mass transfer and increased surface temperature, the shortened contact time causes a reduced CH₄ conversion at high flowrates. The effect of flowrate on the dominant regime is investigated, for both reactants, comparing the resistances calculated in the pure transport regime and in the pure kinetic regime. From a chemical point of view, the model allows for the analysis of the reaction path leading to hydrogen. Due to inhibition of H₂O re-adsorption, it can be proven that H₂ can be a primary product even in the presence of gas phase O₂. The analysis of the surface coverages shows analogous effects on the profiles when decreasing C/O or increasing flow, because in both cases the surface temperature is increased. Syngas selectivity was also evaluated, both from measured and calculated profiles. S_H2 is well described by the model at each stoichiometry and flowrate, while S_CO is underestimated in every case. From this work, it is also indicated that the Rh catalyst works with CO (measured) selectivities higher than equilibrium. Carbon dioxide only forms in the oxidation zone, for C/O = 1 and 1.3, but in the rest of the catalyst zone, there is no further production despite what would be expected from equilibrium. This confirms Rh does not catalyze the water gas shift reaction. On the other hand, at C/O = 0.8, this reaction becomes active, due to the higher temperature, and the CO₂ is also produced in the reforming zone. This suggests that CO₂ will not rise after the oxidation section if the surface temperature is kept sufficiently low. Sensitivity analyses to the active catalytic surface and to the kinetic parameters are provided.     

Syngas production by autothermal reforming of methane on supported platinum catalysts

The performance of supported platinum catalysts on the autothermal reforming of methane was evaluated. The effect of the calcination temperature of the CeZrO₂ support and of the reaction conditions (reaction temperature, presence of CO₂ in the feedstock, and H₂O/CH₄ molar ratio) was studied. The catalysts were characterized by BET, XRD, and OSC analyses and the reaction mechanism was determined by TPSR experiments. The TPSR analyses indicate that autothermal reforming of methane proceeds through a two-step mechanism (indirect mechanism) over all catalysts studied. The Pt/Ce_0.75Zr_0.25O₂ catalyst presented the best stability, which depends not only on the amount of oxygen vacancies of the support but also on the metal particle size. The higher reducibility and oxygen storage/release capacity of Pt/Ce_0.75Zr_0.25O₂ catalyst promote the mechanism of continuous removal of carbonaceous deposits from the active sites, which takes place at the metal-support interfacial perimeter. The water also participates in this mechanism, favouring the carbon removal of metal particle. Furthermore, the reaction conditions influenced significantly the behaviour of Pt/Ce_0.75Zr_0.25O₂ catalysts. The increase of H₂O/CH₄ molar ratio had a beneficial effect on the methane conversion and on the H₂/CO molar ratio. However, the increase of the reaction temperature had an opposite effect. Both the methane conversion and H₂/CO molar ratio decreased with the increasing of reaction temperature. Moreover, the addition of CO₂ to feedstock increased the initial methane conversion, but decreased the stability of the catalyst.     

Effect of different promoters on Ni/CeZrO2 catalyst for autothermal reforming and partial oxidation of methane

Ni/CeZrO₂ catalysts promoted by Ag, Fe, Pt and Pd were investigated for methane autothermal reforming and partial oxidation of methane. The catalysts properties were determined by BET surface area, X-ray diffraction (XRD), H₂ temperature-programmed reduction (TPR), temperature-programmed desorption of CO₂ (CO₂-TPD) and UV–vis diffuse reflectance spectroscopy (DRS). Nickel dispersions were evaluated using a model reaction, the dehydrogenation of cyclohexane. BET surface area results showed that the catalysts prepared by successive impregnation presented lower surface area which favored the smaller nickel dispersion. XRD analysis showed the formation of a ceria–zirconia solid solution. TPR experiments revealed that the addition of Pt and Pd as promoters increased the reducibility of nickel. CO₂-TPD results indicated that the AgNiCZ catalysts presented the best redox properties among all catalysts. The autothermal reforming of methane showed that, among different promoters, the sample modified with silver, AgNiCZ, presented higher methane conversion and better stability during the reaction. These results are related to the good reducibility and to the higher redox capacity observed in TPR and CO₂-TPD analysis. Samples prepared by successive impregnation technique resulted in a smaller catalytic activity. For partial oxidation of methane, just as happened in autothermal reforming, AgNiCZ also presented the best performance during the 24 h of reaction and the addition of silver by successive impregnation resulted in a lower methane conversion, probably, due to the smaller metal dispersion.     

Comparative Study on Thermodynamic Analysis of CO2 Utilization Reactions

Thermodynamic analysis of dimethyl ether (DME) and methane synthesis from CO₂ hydrogenation, and dry reforming of methane was performed using Gibbs free energy minimization. The effects of temperature, pressure, and feed composition on conversion, selectivity, and yield were investigated for each process. High pressure, high H₂/CO₂ ratio, and low temperature favored DME production. The yield of methane during CO₂ methanation increased at lower temperature, higher pressure, and H₂/CO₂ ratio. The yield of synthesis gas improved at higher temperature. Comparison of the three processes demonstrated that the CO₂ conversion was highest during CO₂ methanation reaction if the fraction of CO₂ mol in the feed was less than 0.3. Above this value in the feed, dry reforming allowed the highest CO₂ conversion.     

Partial Oxidation and Dry Reforming of Methane Over Ca/Ni/K(Na) Catalysts

Partial oxidation and dry reforming of methane to synthesis gas over Ca/Ni/K(Na) catalysts have been studied. Effects of temperature, pressure, and oxygen/methane ratios on catalytic activity, selectivity, and carbon formation have been determined. Also reforming of ¹³CH₄ in the presence of CO₂ and Temperature-Programmed Oxidation (TPO) of deposited carbon after the reaction indicated that both methane and CO₂ contribute to carbon formation. The TPO of deposited carbon on Ca/Ni/K catalyst showed that the catalyst consumed a significant amount of oxygen, only a fraction of which was consumed by carbon species on the surface, indicating that the surface oxygen plays a significant role in oxidizing and removing carbon species from the catalyst surfaces     

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.     

CO2 reforming of CH4 in coke oven gas to syngas over coal char catalyst

The CO₂ reforming of methane (in coke oven gas) on the coal char catalyst was performed in a fixed bed reactor at temperatures between 800 and 1200 °C under normal pressure. The effects of the coal char catalyst pretreatment and the ratio of CO₂/CH₄ were studied. Experimental results showed that the coal char was an effective catalyst for production of syngas, and addition of CO₂ did not enhance the CH₄ reforming to H₂. It was also found that the product gas ratio of H₂/CO is strongly influenced by the feed ratio of CO₂/CH₄. The modified coal char catalyst was more active during the CO₂–CH₄ reforming than the coal char catalyst based on the catalyst volume, furthermore the modified catalyst exhibited high activity in CO₂–CH₄ reforming to syngas. The conversion of methane can be divided into two stages. In the first stage, the conversion of CH₄ gradually decreased. In the second stage, the conversion of methane maintained nearly constant. The conversion of CO₂ decreased slightly during the overall reactions in CO₂–CH₄ reforming. The coal char catalyst is a highly promising catalyst for the CO₂ reforming of methane to syngas.     

Methane steam reforming for synthetic diesel fuel production from steam-hydrogasifier product gases

Steam-methane reforming (SMR) reaction was studied using a tubular reactor packed with NiO/γ-Al₂O₃ catalyst to obtain synthesis gases with H₂/CO ratios optimal for the production of synthetic diesel fuel from steam-hydrogasification of carbonaceous materials. Pure CH₄ and CH₄-CO₂ mixtures were used as reactants in the presence of steam. SMR runs were conducted at various operation parameters. Increasing temperature from 873 to 1,023 K decreased H₂/CO ratio from 20 to 12. H₂/CO ratio decreased from 16 to 12 with pressure decreasing from 12.8 to 1.7 bars. H₂/CO ratio also decreased from about 11 to 7 with steam/CH₄ ratio of feed decreasing from 5 to 2, the lowest limit to avoid severe coking. With pure CH₄ as the feed, H₂/CO ratio of synthesis gas could not be lowered to the optimal range of 4–5 by adjusting the operation parameters; however, the limitation in optimizing the H₂/CO ratio for synthetic diesel fuel production could be removed by introducing CO₂ to CH₄ feed to make CH₄-CO₂ mixtures. This effect can be primarily attributed to the contributions by CO₂ reforming of CH₄ as well as reverse water-gas shift reaction, which led to lower H₂/CO ratio for the synthesis gas. A simulation technique, ASPEN Plus, was applied to verify the consistency between experimental data and simulation results. The model satisfactorily simulated changes of H₂/CO ratio versus the operation parameters as well as the effect of CO₂ addition to CH₄ feed.     

Kinetic study of methane reforming with carbon dioxide over NiCeMgAl bimodal pore catalyst

The kinetic behavior of NiCeMgAl bimodal pore catalyst for methane reforming with CO₂ was investigated after the elimination of external and internal diffusion effects in a fixed‐bed reactor as a function of temperature and partial pressures of reactants and products. Increase in CO₂ partial pressure favors the consumptions of CH₄ and CO₂ but inhibits the formation of H₂ due to the existence of reverse water gas shift (RWGS) reaction. The reforming rate increased first and then reached a horizontal stage with the rise of CH₄ partial pressure. A Langmuir–Hinshelwood model was developed assuming that the carbon deposition is ignorable but the RWGS reaction is non‐ignorable and the removal of adsorbed carbon intermediate is the rate‐determining step. A nonlinear least‐square method was applied to solve the kinetic parameters. The derived kinetic expression fits the experimental data very well with a R² above 0.97, and also predicts the products flow rate satisfactorily. © 2016 American Institute of Chemical Engineers AIChE J, 63: 2019–2029, 2017     

Thermodynamic Equilibrium Calculations for the Reforming of Coke Oven Gas with Gasification Gas

Thermodynamic analyses of the reforming of coke oven gas with gasification gas for syngas were investigated as a function of coke oven gas‐to‐gasification gas ratio (1–3), oxygen‐to‐methane ratio (0–1.56), pressure (25–35 bar) and temperature (700–1100 °C). Thermodynamic equilibrium results indicate that the operating temperature should be approximately 1100 °C and the oxygen‐to‐methane ratio should be approximately 0.39, where about 80 % CH₄ and CO₂ can be converted at 30 bar. Increasing the operating pressure shifts the equilibrium toward the reactants (CH₄ and CO₂); increasing the pressure from 25 to 35 bar decreases the conversion of CO₂ from 73.7 % to 67.8 %. The conversion ratio of CO₂ is less than that in the absence of O₂. For a constant feed gas composition (7 % O₂, 31 % gasification gas, and 62 % coke oven gas), a H₂/CO ratio of about 2 occurs at temperatures of 950 °C and above. Pressure effects on the H₂/CO ratio are negligible for temperatures greater than 750 °C. The steam produced has an effect on the hydrogen selectivity, but its mole fraction decreases with temperature; trace amounts of other secondary products are observed.