Thermodynamic analysis of a membrane-assisted chemical looping reforming reactor concept for combined H2 production and CO2 capture

There is great consensus that hydrogen will become an important energy carrier in the future. Currently, hydrogen is mainly produced by steam reforming of natural gas/methane on large industrial scale or by electrolysis of water when high-purity hydrogen is needed for small-scale hydrogen plants. Although the conventional steam reforming process is currently the most economical process for hydrogen production, the global energy and carbon efficiency of this process is still relatively low and an improvement of the process is key for further implementation of hydrogen as a fuel source. Different approaches for more efficient hydrogen production with integrated CO₂ capture have been discussed in literature: Chemical Looping Combustion (CLC) or Chemical Looping Reforming (CLR) and membrane reactors have been proposed as more efficient alternative reactor concepts relative to the conventional steam reforming process. However, these systems still present some drawbacks. In the present work a novel hybrid reactor concept that combines the CLR technology with a membrane reactor system is presented, discussed and compared with several other novel technologies. Thermodynamic studies for the new reactor concept, referred to as Membrane-Assisted Chemical Looping Reforming (MA-CLR), have been carried out to determine the hydrogen recovery, methane conversion as well as global efficiency under different operating conditions, which is shown to compare quite favorably to other novel technologies for H₂ production with CO₂ capture.     

Calcium looping gasification for high-concentration hydrogen production with CO2 capture in a novel compact fluidized bed: Simulation and operation requirements

The coal/CaO/steam gasification system is one of the clean coal technologies being developed for hydrogen production with inherent carbon dioxide separation. A novel reactor configuration for the system is proposed in this paper. It consists of three major counterparts: a gasifier, a riser and a regenerator. A regenerable calcium-based sorbent CaO is used to remove carbon dioxide. In the gasifier, the coal-steam gasification reaction occurs with in situ carbon dioxide removal by carbonation reaction. The removal of carbon dioxide favors the gasification and water-shift reaction equilibrium and enables the production of a hydrogen-rich gas stream. CaO is regenerated in the regenerator by burning the unreacted char with oxygen, and a pure stream of carbon dioxide is separated after a cyclone. The regenerated CaO then flows into the riser above the gasifier, and removes the carbon dioxide in the outlet gases from the gasifier and drives the water-gas shift reaction forward, further improving the hydrogen purity. In this work, the feasibility and optimum process conditions of the proposed system were described. The hydrogen purity can reach 96 vol% at a steam flow 80 mol/s and CaO recycle rate 30 mol/s when the carbon conversion rate is 0.50. Increasing the steam flow and CaO recycle rate can enhance the hydrogen yield and purity. With the rise of operation pressure from 1 bar to 10 bar, the hydrogen yield and purity decrease and methane yield increases. High pressure leads to higher calcination temperature. At 10 bar, the temperature for CaCO₃ decomposition is approximately 1100 °C, at such temperature, the sorbent is easy to deactivate. The appropriate temperatures in the gasifier and the riser are 700 and 600 °C, respectively. An analysis of heat integration is conducted. The maximum carbon conversion rate is ∼0.65. A hydrogen production efficiency of 58.5% is obtained at a carbon conversion rate 0.50, steam flow 60 mol/s and CaO recycle rate 30 mol/s, with a hydrogen purity of 93.7 vol%.     

Low temperature sugar cane bagasse pyrolysis for the production of high purity hydrogen through steam reforming and CO2 capture

Biomass pyrolysis offers a fast route to produce elevated yields towards highly valued liquid products. This research aims the determination of optimal experimental conditions for a slow and low temperature pyrolysis to produce the highest yield towards condensable (CVM) and non-condensable (NCVM) volatile matter from Mexican cane bagasse and to quantify and characterize the compounds that constitute CVM and NCVM obtained. Results indicate that yield towards volatiles is strongly dependent on temperature. The highest yield was achieved at temperatures greater than 500 °C at a heating rate of 10 °C/min, residence time of 60 min and a particle size between of 420 and 840 μm. Product quantification under isothermal conditions determined that at 550 °C the NCVM, CVM and solid residue was of 26, 57 and 16%, respectively. Preliminary thermodynamic analysis of steam reforming and CO₂ absorption reactions using one of the main CVM products resulted in a potential high hydrogen production yield.     

Sorbent enhanced hydrogen production from steam gasification of coal integrated with CO2 capture

In this work, CO₂ capture and H₂ production during the steam gasification of coal integrated with CO₂ capture sorbent were investigated using a horizontal fixed bed reactor at atmospheric pressure. Four different temperatures (650, 675, 700, and 750 °C) and three sorbent-to-carbon ratios ([Ca]/[C] = 0, 1, 2) were studied. In the absence of sorbent, the maximum molar fraction of H₂ (64.6%) and conversion of coal (71.3%) were exhibited at the highest temperature (750 °C). The experimental results verified that the presence of sorbent in the steam gasification of coal enhanced the molar fraction of H₂ to more than 80%, with almost all CO₂ was fixed into the sorbent structure, and carbon monoxide (CO) was converted to H₂ and CO₂ through the water gas shift reaction. The steam gasification of coal integrated with CO₂ capture largely depended on the reaction temperature and exhibited optimal conditions at 675 °C. The maximum molar fraction of H₂ (81.7%) and minimum CO₂ concentration (almost 0%) were obtained at 675 °C and a sorbent-to-carbon ratio of 2.     

An oxy-fuel mass-recirculating process for H2 production with CO2 capture by autothermal catalytic oxyforming of methane

A new oxy-fuel H₂ generation process with CO₂ avoidance is provided. The process utilizes mass recirculation of CO and H₂O to the oxyforming reactor. A comparison between non-recirculating and mass-recirculating oxyforming reactor operation is given. Main benefits of mass recirculation are emphasized. The oxyforming reactor is integrated with the H₂ and CO₂ separators, fuel cell and O₂ generator. In the process C/O is equal to 0.5 while C/H determines the temperature level in the reactor. The reaction system includes combustion, steam reforming and water–gas shift reactions. The oxyforming process is found to be mass transport controlled with O₂ as the limiting reactant. It is emphasized that under MR conditions the decomposition of H₂/CO₂ by water–gas shift reaction is suppressed by means of CO/H₂O-enrichment and hence MR conditions allow for higher temperatures beneficial to endothermic steam reforming reaction. Under MR conditions the thermodynamic equilibrium limits are overcome and all reactions are forced to proceed to the completion which enables 100% selectivities to H₂ and CO₂. The effects of operation parameters such as temperature, flow rate, pressure and composition are examined. The derived S-terms enable for the concise interpretation of the effect of pressure on the concentration gradients transverse to the flow. The consistent control algorithm of the oxyforming reactor is provided.     

Optimization of H2 production with CO2 capture by steam reforming of methane integrated with a chemical-looping combustion system

Methane steam reforming (SR) integrated with a chemical-looping combustion (CLC) system is a new process for producing hydrogen from natural gas, allowing carbon dioxide capture with a low energy penalty. In this study, mass and enthalpy balances of an SR-CLC system were carried out to determine the autothermal operating conditions for optimal H₂ production. The evaluation was conducted using iron-based oxygen carriers. Two configurations were analysed, firstly with the reformer tubes inside the fuel reactor and, secondly, with the reformer tubes inside the air reactor. This paper analyses the effect of two parameters affecting the SR process, namely the conversion of methane in the reformer (XCH₄$X_{{\text{CH}}_4}$) and the efficiency of the hydrogen separation of a pressure swing adsorption (PSA) unit (η_PSA), as well as two parameters affecting the CLC system, namely the Fe₂O₃ content in the oxygen carrier and its conversion variation (ΔX_OC), on the H₂ yields. Moreover, it also analyses the reduction of Fe₂O₃ to Fe₃O₄ or to FeAl₂O₄. The results shown that a H₂ yield value of 2.45 mol H₂ per mol of CH₄ can be obtained with the reformer tubes located inside the air reactor and with Fe₂O₃ being reduced to Fe₃O₄. This corresponds to a CH₄ to H₂ conversion of 74.2%, which is similar to state-of-the-art H₂ production technologies, but with inherent CO₂ capture in the SR-CLC process.     

Hydrogen production from coal gasification for effective downstream CO2 capture

The coal gasification process is used in commercial production of synthetic gas as a means toward clean use of coal. The conversion of solid coal into a gaseous phase creates opportunities to produce more energy forms than electricity (which is the case in coal combustion systems) and to separate CO₂ in an effective manner for sequestration. The current work compares the energy and exergy efficiencies of an integrated coal-gasification combined-cycle power generation system with that of coal gasification-based hydrogen production system which uses water-gas shift and membrane reactors. Results suggest that the syngas-to-hydrogen (H₂) system offers 35% higher energy and 17% higher exergy efficiencies than the syngas-to-electricity (IGCC) system. The specific CO₂ emission from the hydrogen system was 5% lower than IGCC system. The Brayton cycle in the IGCC system draws much nitrogen after combustion along with CO₂. Thus CO₂ capture and compression become difficult due to the large volume of gases involved, unlike the hydrogen system which has 80% less nitrogen in its exhaust stream. The extra electrical power consumption for compressing the exhaust gases to store CO₂ is above 70% for the IGCC system but is only 4.5% for the H₂ system. Overall the syngas-to-hydrogen system appears advantageous to the IGCC system based on the current analysis.     

A novel catalyst–sorbent system for an efficient H2 production with in-situ CO2 capture

This paper presents an experimental investigation for an improved process of sorption-enhanced steam reforming of methane in an admixture fixed bed reactor. A highly active Rh/Ce_αZr_1−αO₂ catalyst and K₂CO₃-promoted hydrotalcite are utilized as novel catalyst/sorbent materials for an efficient H₂ production with in situ CO₂ capture at low temperature (450–500 °C). The process performance is demonstrated in response to temperature (400–500 °C), pressure (1.5–6.0 bar), and steam/carbon ratio (3–6). Thus, direct production of high H₂ purity and fuel conversion >99% is achieved with low level of carbon oxides impurities (<100 ppm). A maximum enhancement of 162% in CH₄ conversion is obtained at a temperature of 450 °C and a pressure of 6 bar using a steam/carbon molar ratio of 4. The high catalyst activity of Rh yields an enhanced CH₄ conversion using much lower catalyst/sorbent bed composition and much smaller reactor size than Ni-based sorption enhanced processes at low temperature. The cyclic stability of the process is demonstrated over a series of 30 sorption/desorption cycles. The sorbent exhibited a stable performance in terms of the CO₂ working sorption capacity and the corresponding CH₄ conversion obtained in the sorption enhanced process. The process showed a good thermal stability in the temperature range of 400–500 °C. The effects of the sorbent regeneration time and the purge stream humidity on the achieved CH₄ conversion are also studied. Using steam purge is beneficial for high degree of CO₂ recovery from the sorbent.     

Promotional effect of alkaline earth over Ni-La2O3 catalyst for CO2 reforming of CH4: Role of surface oxygen species on H2 production and carbon suppression

Alkaline earth elements (Mg, Ca and Sr) on Ni-La₂O₃ catalyst have been investigated as promoters for syngas production from dry CO₂ reforming of methane (DRM). The catalysis results of DRM performance at 600 °C show that the Sr-doped Ni-La₂O₃ catalyst not only yields the highest CH₄ and CO₂ conversions (∼78% and ∼60%) and highest H₂ production (∼42% by vol.) but also has the lowest carbon deposition over the catalyst surface. The XPS, O₂-TPD, H₂-TPR and FTIR results show that the excellent performance over the Sr-doped Ni-La₂O₃ catalyst is attributed to the presence of a high amount of lattice oxygen surface species which promotes C-H activation in DRM reaction, resulting in high H₂ production. Moreover, these surface oxygen species on the Ni-SDL catalyst can adsorb CO₂ molecules to form bidentate carbonate species, which can then react with the surface carbon species formed during DRM, resulting in higher CO₂ conversion and lower carbon formation.     

Iron and nickel doped alkaline-earth catalysts for biomass gasification with simultaneous tar reformation and CO2 capture

The tar reforming catalytic activity of iron and nickel based catalysts supported on alkaline-earth oxides CaO, MgO and calcined dolomite [a (CaMg)O solid solution] has been investigated in a fixed bed reactor operating at temperatures ranging from 650 to 850 °C; toluene and 1-methyl naphthalene were used as model compounds for tar generated during biomass gasification. The CO₂ absorption capacities of Fe/(CaMg)O and Ni/(CaMg)O were also investigated at the lower temperature condition (650 °C) at which the sorption process is thermodynamically favoured. It was found that iron and nickel may be optimised in the substrate particles to enhance both the catalytic activity and the carbon deposition resistance during catalytic tests, at the same time reducing critical limitations on CO₂ capture capacity.     

Recent developments in membrane-based technologies for CO2 capture

Developing new methods and technologies that compete with conventional industrial processes for CO₂ capture and recovery is a hot topic in the current research. Conventional processes do not fit with the current approach of process intensification but take advantage due to their maturity and large-scale implementation. Acting in a precombusion scenario or post-combustion scenario involves the separation of CO₂/H₂ or CO₂/N₂, respectively.     

Catalytic CO2 reforming of CH4 over Cr-promoted Ni/char for H2 production

The objective of the study is to investigate the catalytic performance of Cr-promoted Ni/char in CO₂ reforming of CH₄ at 850 °C. The char obtained from the pyrolysis of a long-flame coal at 1000 °C was used as the support. The catalysts were prepared by incipient wetness impregnation methods with different metal precursor doping sequence. The characterization of the composite catalysts was evaluated by XRD, XPS, SEM-EDS, TEM, H₂-TPR, CO₂-TPD, CH₄-TPSR, and CO₂-TPO. The results indicate that the catalyst prepared by co-impregnation of Ni and Cr possess higher activity than those by sequential impregnation. The optimal loading of Cr on 5 wt% Ni/char is 7.8 wt‰. Moreover, the molar feed ratio of CH₄/CO₂ has a considerable effect on both the stability and the activity of Cr–Ni/char. The main effect of Cr is the great enhance of the adsorption to CO₂. It is interesting that the conversions of CH₄ and CO₂ over Cr-promoted Ni/char and Ni/char decrease initially, following by a steady rise as the reaction proceeds with time-on-stream (TOS). In addition, cyclic tests were conducted and no distinct deterioration in the catalytic performance of the catalysts was observed. On the basis of the obtained results, nickel carbide was speculated to be the active species which was formed during the CO₂ reforming of CH₄ reaction.     

Biomass-fired cogeneration systems with CO2 capture and storage

In this study, we estimate and analyze the CO₂ mitigation costs of large-scale biomass-fired cogeneration technologies with CO₂ capture and storage. The CO₂ mitigation cost indicates the minimum economic incentive required (e.g. in the form of a carbon tax) to make the cost of a less carbon intensive system equal to the cost of a reference system. If carbon (as CO₂) is captured from biomass-fired energy systems, the systems could in principle be negative CO₂ emitting energy systems. CO₂ capture and storage from energy systems however, leads to reduced energy efficiency, higher investment costs, and increased costs of end products compared with energy systems in which CO₂ is vented. Here, we have analyzed biomass-fired cogeneration plants based on steam turbine technology (CHP-BST) and integrated gasification combined cycle technology (CHP-BIGCC). Three different scales were considered to analyze the scale effects. Logging residues was assumed as biomass feedstock. Two methods were used to estimate and compare the CO₂ mitigation cost. In the first method, the cogenerated power was credited based on avoided power production in stand-alone plants and in the second method the same reference output was produced from all systems. Biomass-fired CHP-BIGCC with CO₂ capture and storage was found very energy and emission efficient and cost competitive compared with other conversion systems.     

Techno-economic analysis of the Ca-Cu process integrated in hydrogen plants with CO2 capture

In this work, a techno-economic analysis of a hydrogen production plant based on the Ca-Cu process has been carried out. The simulation of the whole hydrogen production plant has been performed, including the calculation of the Ca-Cu fixed bed reactors system using a sharp front modelling approach. From the analyses carried out, it has been demonstrated that the optimal operation point from the energy performance point of view is reached when fuel needed for sorbent regeneration is entirely supplied by the off-gas from the PSA hydrogen purification unit, which corresponds to operating the plant with the minimum steam-to-carbon ratio in the reforming step. Moreover, lowering the operating pressure of the Ca-Cu system results beneficial from the hydrogen production efficiency, but the CO₂ emissions and the economics worsen.The Ca-Cu based hydrogen production plant operating at a high pressure has been demonstrated to be cost efficient with respect to a benchmark hydrogen production plant based on conventional fired tubular reformer and CO₂ capture by MDEA absorption. A hydrogen production cost of 0.178 €/Nm³ and a CO₂ avoided cost of 30.96 €/ton have been calculated for this Ca-Cu hydrogen production plant, which are respectively 8% and 52% lower than the corresponding costs of the benchmark.     

Enhanced H2 fermentation of organic waste by CO2 sparging

This study aimed to improve the productivity of dark fermentative hydrogen production from organic waste. An anaerobic sequencing batch reactor was used for hydrogen fermentation and it was fed with food waste (VS 4.4 ± 0.2% containing 27 g carbohydrate-COD/L) at various CO₂ sparging rates (40–120 L/L/d), hydraulic retention times (HRTs; 18–42 h), and solid retention times (SRTs; 18–160 h). CO₂ sparging increased the H₂ productivity by 5–36% at all the examined conditions, confirming the benefit of the replacement of headspace gas by CO₂. The maximum H₂ production was obtained by CO₂ sparging at 80 L/L/d, resulting in the H₂ productivity of 3.18 L H₂/L/d and the H₂ yield of 97.3 mL H₂/g VS_added. Increase of n-butyrate and isopropanol yields were concurrent with the enhanced H₂ yield by CO₂ sparging. Acidogenic efficiency, the sum of H₂, organic acid, and alcohol, in the CO₂-sparged reactor ranged from 47.9 to 56.0%, which was comparable to conventional acidogenesis. Thermodynamic analysis confirmed that both CO₂ sparging and CO₂ removal were beneficial for H₂-producing reactions, but CO₂ sparing has more profound effect than CO₂ removal on inhibiting H₂-consuming reactions.     

Coal gasification with in situ CO2 capture by the synthetic CaO sorbent in a 1 kWth dual fluidised-bed reactor

Coal gasification with in situ CO₂ capture is believed to be able to produce highly concentrated H₂ with little or no CO₂ compared with the conventional process. This has been demonstrated by other researchers working on a single fluidised bed by continuously feeding the CaO sorbent. This work presents the results of coal gasification with in situ CO₂ capture by a synthetic CaO sorbent in a 1 kW_th dual fluidised-bed reactor at atmospheric pressure, which has not been reported in the literature. The synthetic CaO sorbent is cyclically used by going through multiple carbonation/calcination cycles during coal gasification.     

Role of CO2 in the CH4 oxidation and H2 formation during fuel-rich combustion in O2/CO2 environments

The effect of CO₂ reactivity on CH₄ oxidation and H₂ formation in fuel-rich O₂/CO₂ combustion where the concentrations of reactants were high was studied by a CH₄ flat flame experiment, detailed chemical analysis, and a pulverized coal combustion experiment. In the CH₄ flat flame experiment, the residual CH₄ and formed H₂ in fuel-rich O₂/CO₂ combustion were significantly lower than those formed in air combustion, whereas the amount of CO formed in fuel-rich O₂/CO₂ combustion was noticeably higher than that in air. In addition to this experiment, calculations were performed using CHEMKIN-PRO. They generally agreed with the experimental results and showed that CO₂ reactivity, mainly expressed by the reaction CO₂ + H → CO + OH (R1), caused the differences between air and O₂/CO₂ combustion under fuel-rich condition. R1 was able to advance without oxygen. And, OH radicals were more active than H radicals in the hydrocarbon oxidation in the specific temperature range. It was shown that the role of CO₂ was to advance CH₄ oxidation during fuel-rich O₂/CO₂ combustion. Under fuel-rich combustion, H₂ was mainly produced when the hydrocarbon reacted with H radicals. However, the hydrocarbon also reacted with the OH radicals, leading to H₂O production. In fact, these hydrocarbon reactions were competitive. With increasing H/OH ratio, H₂ formed more easily; however, CO₂ reactivity reduced the H/OH ratio by converting H to OH. Moreover, the OH radicals reacted with H₂, whereas the H radicals did not reduce H₂. It was shown that OH radicals formed by CO₂ reactivity were not suitable for H₂ formation. As for pulverized coal combustion, the tendencies of CH₄, CO, and H₂ formation in pulverized coal combustion were almost the same as those in the CH₄ flat flame.     

Pre-combustion, post-combustion and oxy-combustion in thermal power plant for CO2 capture

This paper presents a summary of technical-economic studies. It allows evaluating, in the French context, the production cost of electricity derived from coal and gas power plants with the capture of CO₂, and the cost per tonne of CO₂ avoided. Three systems were studied: an Integrated Gasification Combined Cycle (IGCC), a conventional combustion of Pulverized Coal (PC) and a Natural Gas Combined Cycle (NGCC). Three main methods were envisaged for the capture of CO₂: pre-combustion, post-combustion and oxy-combustion.For the IGCC, two gasification types have been studied: a current technology based on gasification of dry coal at 27 bars (Shell or GE/Texaco radiant type) integrated into a classical combined cycle providing 320 MWe, and a future technology (planned for about 2015–2020) based on gasification of a coal–water mixture (slurry) that can be compressed to 64 bars (GE/Texaco slurry type) integrated into an advanced combined cycle (type H with steam cooling of the combustion turbine blades) producing a gross power output of 1200 MWe.     

Ultrasonic spray pyrolysis synthesis of Ag/TiO2 nanocomposite photocatalysts for simultaneous H2 production and CO2 reduction

Simultaneous photocatalytic hydrogen production and CO₂ reduction (to form CO and CH₄) from water using methanol as a hole scavenger were investigated using silver-modified TiO₂ (Ag/TiO₂) nanocomposite catalysts. A simple ultrasonic spray pyrolysis (SP) method was used to prepare mesoporous Ag/TiO₂ composite particles using TiO₂ (P25) and AgNO₃ as the precursors. The material properties and photocatalytic activities were compared with those prepared by a conventional wet-impregnation (WI) method. It was found that the samples prepared by the SP method had a larger specific surface area and a better dispersion of Ag nanoparticles on TiO₂ than those prepared by the WI method, and as a result, the SP samples showed much higher photocatalytic activities toward H₂ production and CO₂ reduction. The optimal Ag concentration on TiO₂ was found to be 2 wt%. The H₂ production rate of the 2% Ag/TiO₂–SP sample exhibited a six-fold enhancement compared with the 2% Ag/TiO₂–WI sample and a sixty-fold enhancement compared with bare TiO₂. The molar ratio of H₂ and CO in the final products can be tuned in the range from 2 to 10 by varying the reaction gas composition, suggesting a viable way of producing syngas (a mixture of H₂ and CO) from CO₂ and water using the prepared Ag/TiO₂ catalysts with energy input from the sun.     

Two novel oxy-fuel power cycles integrated with natural gas reforming and CO2 capture

Two novel system configurations were proposed for oxy-fuel natural gas turbine systems with integrated steam reforming and CO₂ capture and separation. The steam reforming heat is obtained from the available turbine exhaust heat, and the produced syngas is used as fuel with oxygen as the oxidizer. Internal combustion is used, which allows a very high heat input temperature. Moreover, the turbine working fluid can expand down to a vacuum, producing an overall high-pressure ratio. Particular attention was focused on the integration of the turbine exhaust heat recovery with both reforming and steam generation processes, in ways that reduce the heat transfer-related exergy destruction. The systems were thermodynamically simulated, predicting a net energy efficiency of 50–52% (with consideration of the energy needed for oxygen separation), which is higher than the Graz cycle energy efficiency by more than 2 percentage points. The improvement is attributed primarily to a decrease of the exergy change in the combustion and steam generation processes that these novel systems offer. The systems can attain a nearly 100% CO₂ capture.