Mixed oxygen ionic-carbonate ionic conductor membrane reactor for coupling CO2 capture with in situ methanation

CO₂ methanation is one of the vital reactions to utilize CO₂ and realize power to gas process. To decrease the CO₂ capture cost and alleviate the hot spots during the strong exothermic methanation reaction, here, we report a coupling of CO₂ capture process with in situ CO₂ methanation process through a ceramic-molten carbonate (MC) dual phase membrane reactor over the Ni-based catalyst. The performance of the membrane reactor was systematically investigated and compared with the traditional fixed-bed reactor. The results show that the performance of the membrane reactor is higher than that of the fixed-bed reactor, since the produced steam through the methanation process can be partially removed through the dual-phase membrane, which promotes the reaction shift to right side. A stability test shows no obvious degradation within 32 h. These results indicate that the membrane reactor is promising for coupling CO₂ capture with in situ methanation process.     

CO2 Methanation in Microstructured Reactors – Catalyst Development and Process Design

The sulfur tolerance of mono‐ and bimetallic ruthenium catalysts for CO₂ hydrogenation was investigated in microchannel reactors. H₂S was selected as a model compound. It was found that a Ru/CeO₂ catalyst deactivates rapidly. Ni was a much better additive to improve the catalyst stability compared to Rh and serves as a sulfur trap. The influence of the support was evaluated showing that a SiO₂‐supported catalyst has a higher stability and better selectivity compared to CeO₂ and TiO₂. A plant concept was developed comprising two‐step methanation with a first adiabatic reactor stage followed by a plate heat‐exchanger reactor with integrated cooling which allows more than 97 % CO₂ conversion. A pilot plant will be put into operation in connection with a biogas plant and an electrolyser of 50 kW power consumption.     

Kinetics of the methanation of carbon dioxide over a supported Ni-La2O3 catalyst

The kinetics of the methanation of carbon dioxide was investigated using an alumina supported Ni-La₂O₂ catalyst in a differential and integral reactor. In the differential reactor the molar ratio of H₂ to CO₂ was varied from 0.6 to 30. In the integral reactor the rates were measured with up to 90% conversion. Both reactor tests were carried out at temperatures between 513 and 593 K. The experimental results were described by a Langmuir-Hinshelwood type equation. The kinetics can be explained by assuming equilibrium of dissociative carbon dioxide and hydrogen adsorption, and assuming hydrogenation of surface carbon as the rate determining step.     

Hydrogen Production by Sorption‐Enhanced Steam Glycerol Reforming: Sorption Kinetics and Reactor Simulation

Sorption‐enhanced glycerol reforming, an integrated process involving glycerol catalytic steam reforming and in situ CO₂ removal, offers a promising alternative for single‐stage hydrogen production with high purity, reducing the abundant glycerol by‐product streams. This work investigates this process in a fixed‐bed reactor, via a two‐scale, nonisothermal, unsteady‐state model, highlighting the effect of key operating parameters on the process performance. CO₂ adsorption kinetics was investigated experimentally and described by a mathematical reaction‐rate model. The integrated process presents an opportunity to improve the economics of green hydrogen production via an enhanced thermal efficiency process, the exothermic CO₂ adsorption providing the heat to endothermic steam glycerol reforming, while reducing the capital cost by removing the processing steps required for subsequently CO₂ separation. The operational time of producing high‐purity hydrogen can be enhanced by increasing the adsorbent/catalyst volume ratio, by adding steam to the reaction system and by increasing the inlet reactor temperature. © 2012 American Institute of Chemical Engineers AIChE J, 59: 2105–2118, 2013     

Comparative study between fluidized bed and fixed bed reactors in methane reforming combined with methane combustion for the internal heat supply under pressurized condition

The effect of catalyst fluidization on the conversion of methane to syngas in methane reforming with CO₂ and H₂O in the presence of O₂ under pressurized conditions was investigated over Ni and Pt catalysts. Methane and CO₂ conversion in the fluidized bed reactor was higher than those in the fixed bed reactor over Ni_0.15Mg_0.85O catalyst under 1.0 MPa. This reactor effect was dependent on the catalyst properties. Conversion levels in the fluidized and fixed bed reactor were almost the same over MgO-supported Ni and Pt catalysts. It is suggested that this phenomenon is related to the catalyst reducibility. On a catalyst with suitable reducibility, the oxidized catalyst can be reduced with the produced syngas and the reforming activity regenerates in the fluidized bed reactor. Although serious carbon deposition was observed on Ni_0.15Mg_0.85O in the fixed bed reactor, it was inhibited in the fluidized bed reactor.     

A CuO-CeO2 Mixed-Oxide Catalyst for CO Clean-Up by Selective Oxidation in Hydrogen-Rich Mixtures

A CuO-CeO₂ mixed-oxide catalyst was shown experimentally to be highly active and selective for the oxidation of CO in hydrogen-rich mixtures, and an attractive alternative to the noble metal catalysts presently used for CO clean-up in hydrogen mixtures for proton-exchange membrane fuel cells (PEMFC). Although the presence of H₂O and CO₂ in the feed decreased the activity and increased the reaction temperature considerably to achieve a given CO conversion with a reactor, the selectivity profile with respect to the conversion remained virtually the same. The effect of H₂O and CO₂ on the reaction was found to increase the required energy for reduction of the active copper species in the redox cycles undergone during the reaction. The catalyst showed a slow, reversible deactivation, but the activity was restored on heating the catalyst at 300 °C, even under an inert flow. At space velocities above 42 g h m^-3, the catalyst reduced the CO content to less than 10 ppm in the temperature range 166-176 °C for a feed of 1% CO, 1% O₂, 50% H₂, 20% H₂O, 13.5% CO₂ and balance He. Hence, with this catalyst it is feasible to clean up the CO in a single-stage reactor with relatively small excess oxygen, which is in contrast to the typical multistage reactor systems using noble metal catalysts.     

Multiphase CFD Modeling for a Chemical Looping Combustion Process (Fuel Reactor)

There are growing concerns about increasing emissions of greenhouse gases and a looming global warming crisis. CO₂ is a greenhouse gas that affects the climate of the earth. Fossil fuel consumption is the major source of anthropogenic CO₂ emissions. Chemical looping combustion (CLC) has been suggested as an energy‐efficient method for the capture of carbon dioxide from combustion. A chemical‐looping combustion system consists of a fuel reactor and an air reactor. The air reactor consists of a conventional circulating fluidized bed and the fuel reactor is a bubbling fluidized bed. The basic principle involves avoiding direct contact of air and fuel during the combustion. The oxygen is transferred by the oxygen carrier from the air to the fuel. The water in combustion products can be easily removed by condensation and pure carbon dioxide is obtained without any loss of energy for separation. With the improvement of numerical methods and more advanced hardware technology, the time required to run CFD (computational fluid dynamic) codes is decreasing. Hence, multiphase CFD‐based models for dealing with complex gas‐solid hydrodynamics and chemical reactions are becoming more accessible. To date, there are no reports in the literature concerning mathematical modeling of chemical‐looping combustion using FLUENT. In this work, the reaction kinetics models of the (CaSO₄ + H₂) fuel reactor is developed by means of the commercial code FLUENT. The effects of particle diameter, gas flow rate and bed temperature on chemical looping combustion performance are also studied. The results show that the high bed temperature, low gas flow rate and small particle size could enhance the CLC performance.     

Effect of co-feeding carbon dioxide on Fischer–Tropsch synthesis over an iron–manganese catalyst in a spinning basket reactor

The effect of co-feeding CO₂ on the catalytic properties of an Fe–Mn catalyst during Fischer–Tropsch synthesis (FTS) was investigated in a spinning basket reactor by varying added CO₂ partial pressure in the feed gas. It was found that co-feeding CO₂ to syngas did not decrease the activity of the catalyst, on the contrary, a dramatic increase of the activity and an increase of methane selectivity were observed over the catalyst after removal of CO₂ from the feed gas. The addition of CO₂ led to an increase in olefin/paraffin ratios of low carbon hydrocarbons and a slight decrease in C₁₉⁺ selectivity. It also slightly decreased CO₂ formation rate on the catalyst by increasing the rate of reverse step of the water–gas shift (WGS) reaction and pushing the reaction towards equilibrium, and did not remarkably influence the hydrocarbon formation rate. However, the co-feeding CO₂ can significantly increase the water formation rate and the overall oxygenate formation rate under these reaction conditions.     

On the temperature control in a microstructured packed bed reactor for methanation of CO/CO2 mixtures

Microreactor technology is widely used for process intensification and is essential for fast and strongly exothermic reactions exhibiting mass and heat transfer limitations. In the scope of the MINERVE Power‐to‐Gas project, sponsored by KIC InnoEnergy from 2012 to 2015, a micro packed bed reactor was developed for conversion of syngas containing CO₂ into methane. This work focuses on heat removal and temperature control in a manufactured device using syngas throughputs less than 1.4 Nm³/h (10% CO, 7% CO₂, H₂/C = 4) while examining the cooling potential of different cooling fluids, e.g., air, steam and water. © 2016 American Institute of Chemical Engineers AIChE J, 63: 120–129, 2017     

3D CFD Simulation of Reaction Cells,Cooling Cells,and Manifolds of a Flatbed Reactor for CO2 Methanation

The methanation of CO₂ has attracted great interest in recent years as a technology to generate renewable synthetic natural gas and to recycle CO₂ from different sectors. The actual development state of a flatbed reactor for the methanation of pure stoichiometric feed gas is presented. Additionally, computational fluid dynamics (CFD)-based design strategies are introduced which can be applied for the development and optimization of different processing units. The results of the reactor development demonstrate a good heat exchange and flow distribution in the reactor.     

Numerical study of biomass gasification combined with CO2 absorption in a bubbling fluidized bed

Biomass gasification combined with CO₂ absorption-enhanced reforming (AER) in a bubbling fluidized bed (BFB) reactor is numerically studied via the multiphase particle-in-cell (MP-PIC) method featuring thermochemical and polydispersity sub-models. A novel bubble detection algorithm is proposed for efficiently characterizing bubble morphology. The effects of several crucial operating parameters on the microscale particle behaviors, mesoscale bubble dynamics, and macroscale reactor performance of the AER gasification process are analyzed. Compared with conventional gasification, AER gasification reduces the CO₂ concentration by 33.58% but elevates the H₂ concentration by 32.13%. Higher operating temperature and steam-to-biomass (S/B) ratio promote H₂ generation but deteriorate gasification performance. A lower operating pressure improves gas–solid contact efficiency and gasification performance as the increased operating pressure inhibits bubble dynamics and particle kinematics. Compared with pure sand as bed material, the mixed bed material (CaO:sand = 1:1) significantly improves gasification performance by enhancing H₂ generation and CO₂ removal.     

Enhanced hydroformylation by carbon dioxide‐expanded media with soluble Rh complexes in nanofiltration membrane reactors

A novel process for continuous hydroformylation in CO₂‐expanded liquids (CXLs) is demonstrated using bulky phosphite ligands that are effectively retained in the stirred reactor by a nanofiltration membrane. The reactor is operated at 50°C with a syngas pressure of 0.6 MPa to avoid CO inhibition of reaction rate and selectivity. The nanofiltration pressure is provided by ～3.2 MPa CO₂ that expands the hydroformylation mixture and increases the H₂/CO ratio in the CXL phase resulting in enhanced turnover frequency (～340 h^?1), aldehydes selectivity (>90%) and high regioselectivity (n/i ～8) at nearly steady operation. The use of pressurized CO₂ also reduces the viscosity in the CXL phase, thereby improving the mass‐transfer properties. Constant permeate flux is maintained during the 50 h run with Rh leakage being less than 0.5 ppm. This technology concept has potential applications in homogeneous catalytic processes to improve resource utilization and catalyst containment for practical viability. © 2013 American Institute of Chemical Engineers AIChE J, 59: 4287–4296, 2013     

Characteristics of carbon dioxide hydrogenation in a fluidized bed reactor

Characteristics of CO₂ hydrogenation were investigated in a fluidized bed reactor (0.052 m IDxl.5 m in height). Coprecipitated Fe-Cu-K-Al catalyst (d_ρ=75–90 Μm) was used as a fluidized solid phase. It was found that the CO₂ conversion decreases but the CO selectivity increases, whereas the space-time-yield attains maximum values with increasing gas velocity. The CO₂ conversion has increased, but CO selectivity has decreased with increasing hydrogenation temperature, pressure or H₂/CO₂ ratio in the fluidized bed reactor. Also, the CO, conversion and olefin selectivity appeared to be higher in the fluidized bed reactor than those of the fixed bed reactor. Presented at the Int’l Symp. on Chem. Eng. (Cheju, Feb. 8–10, 2001), dedicated to Prof. H. S. Chun on the occasion of his retirement from Korea University     

A novel carbonized polydopamine (C‐PDA) adsorbent with high CO2 adsorption capacity and water vapor resistance

Novel carbonized polydopamine adsorbents (C‐PDAs) with high surface area, high CO₂ adsorption capacity and superior moisture resistance performance were prepared by one‐step synthesis method using polydopamine as carbon precursor at different KOH/C ratios, and then characterized. CO₂ and water vapor adsorption performances of C‐PDAs were examined separately by static adsorption and fixed‐bed experiments. Results showed that BET area and pore volume of C‐PDA‐4 were up to 3342 m²/g and 2.01 cm³/g, respectively. Its CO₂ adsorption capacity reached up to 30.5 mmol/g at 25 bar, much higher than many other adsorbents including metal‐organic frameworks (MOFs). C‐PDAs prepared with high KOH/C ratios had low surface element concentrations of O and N resulting in low surface hydrophilic property. H₂O(g) isotherm of C‐PDA was much lower than those on Mg‐MOF‐74, Cu‐BTC, and MIL‐101(Cr). Fixed‐bed experiments showed that co‐presence of water vapor in feed stream with 30% RH had negligible impact on CO₂ working capacity of C‐PDA. © 2016 American Institute of Chemical Engineers AIChE J, 62: 3730–3738, 2016     

Cu/ZnO/AlOOH catalyst for methanol synthesis through CO<Subscript>2</Subscript> hydrogenation

Catalytic conversion of CO₂ to methanol is gaining attention as a promising route to using carbon dioxide as a new carbon feedstock. AlOOH supported copper-based methanol synthesis catalyst was investigated for direct hydrogenation of CO₂ to methanol. The bare AlOOH catalyst support was found to have increased adsorption capacity of CO₂ compared to conventional Al₂O₃ support by CO₂ temperature-programmed desorption (TPD) and FT-IR analysis. The catalytic activity measurement was carried out in a fixed bed reactor at 523 K, 30 atm and GHSV 6,000 hr^?1 with the feed gas of CO₂/H₂ ratio of 1/3. The surface basicity of the AlOOH supported Cu-based catalysts increased linearly according to the amount of AlOOH. The optimum catalyst composition was found to be Cu : Zn : Al=40 : 30 : 30 at%. A decrease of methanol productivity was observed by further increasing the amount of AlOOH due to the limitation of hydrogenation rate on Cu sites. The AlOOH supported catalyst with optimum catalyst compositions was slightly more active than the conventional Al₂O₃ supported Cu-based catalyst.     

Effect of bed height on the carbon dioxide capture by carbonation/regeneration cyclic operations using dry potassium-based sorbents

The effect of bed height on CO₂ capture was investigated by carbonation/regeneration cyclic operations using a bubbling fluidized bed reactor. We used a potassium-based solid sorbent, SorbKX35T5 which was manufactured by the Korea Electric Power Research Institute. The sorbent consists of 35% K₂CO₃ for absorption and 65% supporters for mechanical strength. We used a fluidized bed reactor with an inner diameter of 0.05 m and a height of 0.8 m which was made of quartz and placed inside of a furnace. The operating temperatures were fixed at 70 °C and 150 °C for carbonation and regeneration, respectively. The carbonation/regeneration cyclic operations were performed three times at four different L/D (length vs diameter) ratios such as one, two, three, and four. The amount of CO₂ captured was the most when L/D ratio was one, while the period of maintaining 100% CO₂ removal was the longest as 6 minutes when L/D ratio was three. At each cycle, CO₂ sorption capacity (g CO₂/g sorbent) was decreased as L/D ratio was increased. The results obtained in this study can be applied to design and operate a large scale CO₂ capture process composed of two fluidized bed reactors. This work was presented at the 7 ^th China-Korea Workshop on Clean Energy Technology held at Taiyuan, Shanxi, China, June 26–28, 2008.     

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     

Coupling of highly exothermic and endothermic reactions in a metallic monolith catalyst reactor: A preliminary experimental study

An LaFe_0.5Mg_0.5O₃/Al₂O₃/FeCrAl metallic monolith catalyst for the exothermic catalytic combustion of methane and an Ni/SBA-15/Al₂O₃/FeCrAl metallic monolith catalyst for the endothermic reforming of methane with CO₂ have been prepared. A laboratory-scale tubular jacket reactor with the Ni/SBA-15/Al₂O₃/FeCrAl catalyst packed into its outer jacket and the LaFe_0.5Mg_0.5O₃/Al₂O₃/FeCrAl catalyst packed into its inner tube was devised and constructed. The reactor allows a coupling of the exothermic and endothermic reactions by virtue of their thermal matching. An experimental study in which the temperature difference between the chamber of the external electric furnace and the metallic monolith catalyst bed in the jacket was kept very small, by adjusting the power supply to the furnace, confirmed that the heat absorbed in the reforming reaction does indeed partly come from that evolved in the catalytic combustion of methane, and that the direct thermal coupling of the two reactions in the reactor can be realized in practice. When the temperature of the electric furnace chamber was 1088 K, and the gas hourly space velocities (GHSVs) of the reactant mixtures passed through the inner tube and the jacket were 382 h⁻¹ and 40 h⁻¹, respectively, the conversions of methane and CO₂ in the reforming reaction were 93.6% and 91.7%, respectively, and the heat efficiency reached 81.9%. Stability tests showed that neither catalyst underwent deactivation during 150 h on stream.     

Enrichment of coal‐bed methane by PSA complemented with CO2 displacement

A PSA cycle complemented with CO₂ displacement was studied for enriching coal‐bed methane (CBM). The column was first pressurized to the adsorption pressure with feed gas, and then N₂ was produced at column top in step 2. The feed gas switched to CO₂ at the end of step 2, and the adsorbed CH₄ was displaced and pushed to column top by CO₂ becoming the second column‐top product in step 3. The CO₂ stream was shut off before it broke through the sorption bed. Then bed regeneration followed. A series of CH₄/N₂ mixtures containing 17.62 to 51.33% CH₄ was used for feed gas. It was experimentally shown that the product concentration was higher than 90%, and methane recovery was higher than 98% even for the feed of low‐methane concentration. Displacement at ambient pressure was shown more efficient than the displacement at adsorption pressure for the enrichment. © 2010 American Institute of Chemical Engineers AIChE J, 2011