Discovery of novel zeolites for natural gas purification through combined material screening and process optimization

An efficient computational screening approach is proposed to select the most cost‐effective materials and adsorption process conditions for CH₄/CO₂ separation. The method identifies eight novel zeolites for removing CO₂ from natural gas, coalbed methane, shale gas, enhanced oil recovery gas, biogas, and landfill gas sources. The separation cost is minimized through hierarchical material screening combined with rigorous process modeling and optimization. Minimum purity and recovery constraints of 97 and 95%, respectively, are introduced to meet natural gas pipeline specifications and minimize losses. The top zeolite, WEI, can recover methane as economically as $0.15/MMBTU from natural gas with 5% CO₂ to $1.44/MMBTU from natural gas with 50% CO₂, showing the potential for developing natural gas reservoirs with higher CO₂ content. The necessity of a combined material selection and process optimization approach is demonstrated by the lack of clear correlation between cost and material‐centric metrics such as adsorption selectivity. © 2014 American Institute of Chemical Engineers AIChE J, 60: 1767–1785, 2014     

Sustainable design and synthesis of algae‐based biorefinery for simultaneous hydrocarbon biofuel production and carbon sequestration

The superstructure optimization of algae‐based hydrocarbon biorefinery with sequestration of CO₂ from power plant flue gas is proposed. The major processing steps include carbon capture, algae growth, dewatering, lipid extraction and power generation, and algal biorefinery. We propose a multiobjective mixed‐integer nonlinear programming (MINLP) model that simultaneously maximizes the net present value (NPV) and minimizes the global warming potential (GWP) subject to technology selection constraints, mass balance constraints, energy balance constraints, technoeconomic analysis constraints, and environmental impact constraints. The model simultaneously determines the optimal decisions that include production capacity, size of each processing unit, mass flow rates at each stage of the process, utility consumption, economic, and environmental performances. We propose a two‐stage heuristic solution algorithm to solve the nonconvex MINLP model. Finally, the bicriteria optimization problem is solved with ε‐constraint method, and the resulting Pareto‐optimal curve reveals the trade‐off between the economic and environmental criteria. The results show that for maximum NPV, the optimal process design uses direct flue gas, a tubular photobioreactor for algae growth, a filtration dewatering unit, and a hydroprocessing pathway leading to 47.1 MM gallons of green diesel production per year at $6.33/gal corresponding to GWP of 108.7 kg CO₂‐eq per gallon. © 2013 American Institute of Chemical Engineers AIChE J, 59: 1599–1621, 2013     

Transient Effects during Dynamic Operation of a Wall‐Cooled Fixed‐Bed Reactor for CO2 Methanation

The power‐to‐gas process is an option to transform fluctuating renewable electric energy into methane via water electrolysis and subsequent conversion of H₂ by methanation with CO₂. The dynamic behavior of the methanation reactor may then be a critical aspect. The kinetics of CO₂ methanation on a Ni‐catalyst were determined under isothermal and stationary conditions. Transient isothermal kinetic experiments showed a fast response of the rate on step changes of the concentrations of H₂, CO₂; in case of H₂O, the response was delayed. Non‐isothermal experiments were conducted in a wall‐cooled fixed‐bed reactor. Temperature profiles were measured and the effect of a changing volumetric flow was studied. The experimental data were compared with simulations by a transient reactor model.     

Entwicklung eines optimalen CO2‐Abtrennungsprozesses für die oxidative Kopplung von Methan im Miniplant‐Maßstab

Oxidative coupling of methane (OCM) is a promising route for the production of ethylene by using natural gas. However, an industrial implementation still remains in its very early stage with the main efforts focused on the search for a sufficiently selective, active, and stable catalyst. During the OCM reaction, CO₂ is formed as unwanted by‐product and has to be separated in the downstream process. This affects the efficiency of the overall process significantly. For this purpose, an integrated gas treatment process for the CO₂ capture in a mini plant scale has been built.     

Synthesis Gas Production Configurations for Gas‐to‐Liquid Applications

Different syngas configurations in a gas‐to‐liquid plant are studied including autothermal reformer (ATR), combined reformer, and series arrangement of gas‐heated reformer and ATR. The Fischer‐Tropsch (FT) reactor is based on a cobalt catalyst and the degrees of freedom are steam‐to‐carbon ratio, purge ratio of light ends, amount of tail gas recycled to synthesis gas (syngas) and FT synthesis units, and reactor volume. The production rate of liquid hydrocarbons is maximized for each syngas configuration. Installing a steam methane reformer in front of an ATR will reduce the total oxygen consumption per barrel of product by 40 % compared to the process with only an ATR. The production rate of liquid hydrocarbons is increased by 25.3 % since the flow rate of the purge stream for the ATR is the highest one compared to other configurations and contains mainly CO₂.     

Catalytic Methane Decomposition to Hydrogen over a Surface‐Protected Core‐Shell Ni@SiO2 Catalyst

Methane decomposition is a promising method to obtain CO_x‐free hydrogen. The main difficulty of this process is that the produced carbon would deposit on the active phase of the catalyst, leading to catalyst deactivation. In this study, a core‐shell‐structured composite catalyst comprising highly active Ni nanoparticles (NP) as core and mesoporous silica as shell is introduced. The silica shells were synthesized by using cetyltrimethylammonium bromide as template and tetraethyl orthosilicate as precursor. Ni NP and Ni@SiO₂ were examined as catalysts for hydrogen production by methane decomposition at different temperatures and gas hourly space velocities. The results show that the core‐shell catalyst exhibited much better stability in methane decomposition than Ni NP without silica shell and a traditional supported catalyst.     

Multiobjective optimization of product and process networks: General modeling framework,efficient global optimization algorithm,and case studies on bioconversion

A comprehensive optimization model that can determine the most cost‐effective and environmentally sustainable production pathways in an integrated processing network is needed, especially in the bioconversion space. We develop the most comprehensive bioconversion network to date with 193 technologies and 129 materials/compounds for fuels production. We consider the tradeoff between scaling capital and operating expenditures (CAPEX and OPEX) as well as life cycle environmental impacts. Additionally, we develop a general network‐based modeling framework with nonconvex terms for CAPEX. To globally optimize the nonlinear program with high computational efficiency, we develop a specialized branch‐and‐refine algorithm based on successive piecewise linear approximations. Two case studies are considered. The optimal pathways have profits from ?$12.9 to $99.2M/yr, and emit 791 ton CO₂‐eq/yr to 31,571 ton CO₂‐eq/yr. Utilized technologies vary from corn‐based fermentation to pyrolysis. The proposed algorithm reduces computational time by up to three orders of magnitude compared to general‐purpose global optimizers. © 2014 American Institute of Chemical Engineers AIChE J, 61: 530–554, 2015     

One‐dimensional productivity assessment for on‐field methane hydrate production using CO2/N2 mixture gas

The direct recovery of methane from gas hydrate‐bearing sediments is demonstrated, where a gaseous mixture of CO₂ + N₂ is used to trigger a replacement reaction in complex phase surroundings. A one‐dimensional high‐pressure reactor (8 m) was designed to test the actual aspects of the replacement reaction occurring in natural gas hydrate (NGH) reservoir conditions. NGH can be converted into CO₂ hydrate by a “replacement mechanism,” which serves double duty as a means of both sustainable energy source extraction and greenhouse gas sequestration. The replacement efficiency controlling totally recovered CH₄ amount is inversely proportional to CO₂ + N₂ injection rate which directly affecting solid ‐ gas contact time. Qualitative/quantitative analysis on compositional profiles at each port reveals that the length more than 5.6 m is required to show noticeable recovery rate for NGH production. These outcomes are expected to establish the optimized key process variables for near future field production tests. © 2014 American Institute of Chemical Engineers AIChE J, 61: 1004–1014, 2015     

Modular methanol manufacturing from shale gas: Techno‐economic and environmental analyses of conventional large‐scale production versus small‐scale distributed,modular processing

This article presents comparative techno‐economic and environmental analyses of four representative shale gas monetization options, namely, conventional shale gas processing, large‐scale methanol manufacturing, modular methanol manufacturing with shale gas supplied by pipelines, and modular methanol manufacturing with consideration of plant relocation. We first present shale gas supply models for the four gas monetization options. Next, the process designs for shale gas processing and methanol manufacturing from shale gas are described. We develop detailed process simulation models for shale gas processing and methanol manufacturing with different scales using raw shale gas extracted from the Marcellus, Eagle Ford, and Bakken shale plays. On this basis, techno‐economic analyses and environmental impact analyses are conducted for the four shale gas monetization options to systematically compare their economic and environmental performances based on the same conditions. The results show that modular methanol manufacturing is more economically competitive than conventional shale gas processing, although it leads to higher environmental impacts. Besides, modular methanol manufacturing is better than large‐scale methanol manufacturing for raw shale gas produced from distributed, remote wells from both economic and environmental perspectives. © 2017 American Institute of Chemical Engineers AIChE J, 64: 495–510, 2018     

Separation of Methane and Carbon Dioxide Gas Mixtures Using Activated Carbon Modified with 2‐Methylimidazole

Activated carbon was modified by loading 2‐methylimidazole (mIm), ethanol, and glycol onto its surface and adopted to capture CO₂ using the absorption‐adsorption method. The modified activated carbon showed high selectivity for separating CH₄+CO₂ gas mixtures, compared with other methods to modify activated carbon given in the literature. The separation factor was 4.75 times higher than that for the fresh activated‐carbon system, and the separation performance of the activated carbon increased with increasing amount of mIm. The addition of glycol showed greater potential to enhance the selectivity of the activated carbon than ethanol. A recycling test verified the stability of the modified activated carbon for CH₄+CO₂ gas mixture separation.     

Computer-aided process intensification of natural gas to methanol process

The recent revolution in shale gas has presented opportunities for distributed manufacturing of key commodity chemicals, such as methanol, from methane. However, the conventional methane-to-methanol process is energy intensive which negatively affects the profitability and sustainability. We report an intensified process configuration that is both economically attractive and environmentally sustainable. This flowsheet is systematically discovered using the building block-based representation and optimization methodology. The new process configuration utilizes membrane-assisted reactive separations and can have as much as 190% higher total annual profit compared to a conventional configuration. Additionally, it has 57% less CO₂-equivalent greenhouse gas emission. Such drastic improvement highlights the advantages of building block-based computer-aided process intensification method.     

Hybrid FSC membrane for CO2 removal from natural gas: Experimental,process simulation,and economic feasibility analysis

The novel fixed‐site‐carrier (FSC) membranes were prepared by coating carbon nanotubes reinforced polyvinylamine/polyvinyl alcohol selective layer on top of ultrafiltration polysulfone support. Small pilot‐scale modules with membrane area of 110–330 cm² were tested with high pressure permeation rig. The prepared hybrid FSC membranes show high CO₂ permeance of 0.084–0.218 m³ (STP)/(m² h bar) with CO₂/CH₄ selectivity of 17.9–34.7 at different feed pressures up to 40 bar for a 10% CO₂ feed gas. Operating parameters of feed pressure, flow rate, and CO₂ concentration were found to significantly influence membrane performance. HYSYS simulation integrated with ChemBrane and cost estimation was conducted to evaluate techno‐economic feasibility of a membrane process for natural gas (NG) sweetening. Simulation results indicated that the developed FSC membranes could be a promising candidate for CO₂ removal from low CO₂ concentration (10%) NGs with a low NG sweetening cost of 5.73E?3 $/Nm³ sweet NG produced. © 2014 American Institute of Chemical Engineers AIChE J 60: 4174–4184, 2014     

The reaction of NiO/NiAl2O4 particles with alternating methane and oxygen

The reduction and oxidation behaviour of oxygen carrier particles of NiO and NiAl₂O₄ has been investigated in a fluidized bed reactor as well as a thermogravimetric analyzer (TGA). The particles showed high reactivity and gas yield to CO₂ with methane in the temperature interval 750–950°C. In the fluidized bed the yield to CO₂ was between 90 and 99% using bed masses corresponding to 16–57 kg/MW_fuel. Complementary experiments in a TGA at 750 and 950°C showed a clear reaction of the NiAl₂O₄ with CH₄ at the higher temperature. There was methane released from the reactor at high degrees of solid oxidation, which is likely associated with the lack of Ni‐sites on the particles which can reform the methane. There was some carbon formation during the reduction, although the amount was minor when the gas yield to carbon dioxide and degree of oxidation of the solid was high. A simple reactor model using kinetic data from a previous study predicted the gas yield during the reduction in the fluidized bed experiments with reasonable accuracy. The oxygen carrier system investigated in this work shows high promise for use in a real CLC system, provided that the particle manufacturing process can be scaled up with reasonable cost.     

CO2 capture efficiency in post‐combustion using MWNT‐PAA in a packed bed column

The adsorption capacity of polyaspartamide (PAA) and multi‐wall carbon nanotubes with polyaspartamide (MWNT‐PAA) was investigated through a packed bed column with the flowing of flue gas composed of 15 % CO₂, 5 % O₂ and the balance N₂. The adsorption performed at 25 °C, 110 kPa and inlet gas flow rate of 60 mL/min resulted in high CO₂ adsorption capacity of 5.70 and 10.20 mmol‐CO₂/g for PAA and MWNT‐PAA, respectively. The adsorption kinetics was very high, so 7 min were enough for the effluent gas to reach the breakthrough after saturation. The consistency of adsorbents in recurring regeneration was successful through a continuous TSA system of 10 cycle adsorption‐desorption with temperatures of 25–100 °C. The evaluation of heat through differential scanning calorimetry (DSC) resulted in exothermic adsorption with heat release of 45.14 kJ/mol and 124.38 kJ/mol for PAA and MWNT‐PAA, respectively. The heat release was found favourable to promote the desorption as the temperature could rise after adsorption. This is an advantage for energy efficiency, as it depicts the potential of energy recovery. Thus, both adsorbent PAA and MWNT‐PAA were demonstrated to be promising for CO₂ adsorption capture in post‐combustion.     

气煤联供实现资源高效利用和碳减排技术进展

为解决煤化工过程资源利用率低和碳排放高的问题,有研究者提出以天然气、焦炉气、页岩气等富氢资源和煤炭资源联供方案,旨在实现源头碳减排。文章指出依据联供过程技术的差异,较有代表性的方案可分为集成甲烷部分氧化和集成甲烷干/水蒸气重整的气煤联供过程。文章以生产甲醇为例,从资源利用和经济效益等方面对集成甲烷部分氧化和集成甲烷干/水蒸气重整的气煤联供过程进行分析和比较。集成甲烷部分氧化的工艺碳元素利用率达到57.9%,每吨甲醇排放CO₂为1.50t,较传统煤制甲醇工艺排放减少37.5%。甲醇产品成本稍低于传统工艺。集成甲烷干/水蒸气重整工艺的碳元素利用率最高,达到83.7%。减排效果最明显,每吨甲醇排放CO₂为0.90t,较传统工艺排放减少62.5%,但是由于CO₂转化增加能耗,甲醇产品成本有所提升。由于气煤联供过程有利于CO₂减排,当碳税高于65CNY/tCO₂时,两个气煤联供工艺的生产成本低于传统的煤制甲醇工艺。     

CO2 sorption performance by aminosilane functionalized spheres prepared via co‐condensation and post‐synthesis methods

Amine functionalized silica microspheres were synthesised via a modified Stöber reaction for carbon dioxide (CO₂) adsorption. A number of adsorbents were synthesized by co‐condensation and post synthesis immobilization of amines on porous silica spheres. CO₂ adsorption studies were carried out on a fixed bed gas adsorption rig with online mass spectrometry. Amine co‐condensed silica spheres were found to adsorb up to 66 mg CO₂ g^?1 solid in a 0.15 atm CO₂ stream at 35°C. Simple post‐synthesis addition of aminopropyltriethoxysilane to amine co‐condensed silica was found to significantly increase the uptake of CO₂ to 211 mg CO₂ g^?1 under similar conditions, with CO₂ desorption commencing at temperatures as low as 60°C. The optimum temperature for adsorption was found to be 35°C. This work presents a CO₂ adsorbent prepared via a simple synthesis method, with a high CO₂ adsorption capacity and favorable CO₂ adsorption/desorption performance under simulated flue gas conditions. © 2016 American Institute of Chemical Engineers AIChE J, 62: 2825–2832, 2016     

CO2 utilization for methanol production; Optimal pathways with minimum GHG reduction cost

Mitigating CO₂ emissions from industries and other sectors of our economy is a critical component of building a sustainable economy. This paper investigates two different methanol synthesis routes based on CO₂ utilization (CO₂ capture and utilization [CCU], and tri-reforming of methane [TRM]), and compares the results with the conventional methanol production using natural gas as the feedstock (NG-MeOH). A comprehensive techno-economic analysis (TEA) model that includes the findings of the life cycle assessment (LCA) models of methanol production using various CO₂ utilization pathways is conducted. Economic analysis is conducted by developing a cost model that is connected to the simulation models for each production route. Compared to the conventional process (with a GHG emission of 0.6 kg CO₂/kg MeOH), the lifecycle GHG reduction of 1.75 and 0.41 kg CO₂/kg MeOH are achievable in the CCU and TRM pathways, respectively. Furthermore, the results indicate that, under current market conditions and hydrogen production costs, methanol production via CO₂ hydrogenation will result in a cost approximately three times higher than that of the conventional process. The integrated TEA–LCA model shows that this increased cost of production equates to a required life cycle GHG reduction credit of $279 to $422 per tonne of CO₂ utilized, depending on construction material and selected pathway. Additionally, when compared to the CO₂ hydrogenation route, the tri-reforming process (TRM-MeOH) can result in a 42% cost savings. Furthermore, a minimum financial support of $56 per tonne utilized CO₂ will be required to make the TRM-MeOH process economically viable.     

Gas solubility in long‐chain imidazolium‐based ionic liquids

The gas solubility in 1‐dodecyl‐3‐methylimidazolium [C₁₂MIM] based ionic liquids (ILs) was measured at temperatures (333.2, 353.2, and 373.2) K and pressures up to 60 bar for the first time. The popular UNIFAC‐Lei model was successfully extended to long‐chain imidazolium‐based IL and gas (CO₂, CO, and H₂) systems. The free volume theory was used to explain the gas solubility and selectivity in imidazolium‐based ILs by calculating the fractional free volume and free volume by the COSMO‐RS model. Furthermore, the excess enthalpy of gas‐IL system was concerned to provide new insights into temperature dependency of gas (CO₂, CO, and H₂) solubility in ILs. The experimental data, calculation, and theoretical analysis presented in this work are important in gas separations with ILs or supported ionic liquid membranes. © 2017 American Institute of Chemical Engineers AIChE J, 63: 1792–1798, 2017     

Global optimization for sustainable design and synthesis of algae processing network for CO2 mitigation and biofuel production using life cycle optimization

Global optimization for sustainable design and synthesis of a large‐scale algae processing network under economic and environmental criteria is addressed. An algae processing network superstructure including 7800 processing routes is proposed. Based on the superstructure, a multiobjective mixed‐integer nonlinear programming (MINLP) model is developed to simultaneously optimize the unit cost and the unit global warming potential (GWP). To efficiently solve the nonconvex MINLP model with separable concave terms and mixed‐integer fractional terms in the objective functions, a global optimization strategy that integrates a branch‐and‐refine algorithm based on successive piecewise linear approximations is proposed and an exact parametric algorithm based on Newton's method. Two Pareto‐optimal curves are obtained for biofuel production and biological carbon sequestration, respectively. The unit annual biofuel production cost ranges from $7.02/gasoline gallon equivalent (GGE) to $9.71/GGE, corresponding to unit GWP's of 26.491 to 16.52 kg CO₂‐eq/GGE, respectively. © 2014 American Institute of Chemical Engineers AIChE J, 60: 3195–3210, 2014     

Comparison of Oleo‐ vs Petro‐Sourcing of Fatty Alcohols via Cradle‐to‐Gate Life Cycle Assessment

Alcohol ethoxylates surfactants are produced via ethoxylation of fatty alcohol (FA) with ethylene oxide. The source of FA could be either palm kernel oil (PKO) or petrochemicals. The study aimed to compare the potential environmental impacts for PKO‐derived FA (PKO‐FA) and petrochemicals‐derived FA (petro‐FA). Cradle‐to‐gate life cycle assessment has been performed for this purpose because it enables understanding of the impacts across the life cycle and impact categories. The results show that petro‐FA has overall lower average greenhouse gas (GHG) emissions (～2.97 kg CO₂e) compared to PKO‐FA (～5.27 kg CO₂e). (1) The practices in land use change for palm plantations, (2) end‐of‐life treatment for palm oil mill wastewater effluent and (3) end‐of‐life treatment for empty fruit bunches are the three determining factors for the environmental impacts of PKO‐FA. For petro‐FA, n‐olefin production, ethylene production and thermal energy production are the main factors. We found the judicious decisions on land use change, effluent treatment and solid waste treatment are key to making PKO‐FA environmentally sustainable. The sensitivity results show the broad distribution for PKO‐FA due to varying practices in palm cultivation. PKO‐FA has higher impacts on average for 12 out of 18 impact categories evaluated. For the base case, when accounted for uncertainty and sensitivity analyses results, the study finds that marine eutrophication, agricultural land occupation, natural land occupation, fossil depletion, particulate matter formation, and water depletion are affected by the sourcing decision. The sourcing of FA involves trade‐offs and depends on the specific practices through the PKO life cycle from an environmental impact perspective.