Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “catalyst regeneration”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Cobalt-Group 13 Complexes Catalyze CO 2 Hydrogenation via a Co(-I)/Co(I) Redox Cycle

The Co(-I) dihydrogen complexes, [(η 2 -H 2 )CoML]-, where ML is the group 13 metalloligand, N(o-(NCH 2 PiPr 2 )C 6 H 4 ) 3 M, and M is Al, Ga, or In, were previously reported ( J. Am. Chem. Soc. 2017, 139, 6570-6573). In this work, the related Co(-I) end-on dinitrogen adducts, [(N 2 )CoML]-, were isolated and investigated as precatalysts for CO 2 hydrogenation. The Co–Ga catalyst was highly active, achieving 19,200 formate turnovers with an initial turnover frequency of 27,000 h –1 under 34 atm of 1:1 CO 2 /H 2 and using Verkade’s proazaphosphatrane as a base at ambient temperature. The Co–Al catalyst was moderately active, while the Co–In complex was inactive. Hence, tuning the group 13 ion greatly influences the catalytic activity at the Co site. To elucidate the role of the group 13 support, experimental and theoretical mechanistic studies of the Co–Ga and Co–Al catalysts were conducted. The Co(-I) H 2 species are potent hydride donors with estimated thermodynamic hydricities (ΔG° H– ) of 32.0(1) and 37.4(1) kcal/mol in CH 3 CN for M = Al and Ga, respectively. By acting as masked Co(I) dihydrides, the Co(-I) H 2 species operate via an unusual Co(-I)/Co(I) redox cycle. After hydride transfer to CO 2 , the resulting intermediate is the Co(I) hydride complex, HCoML, which was independently synthesized and structurally characterized for M = Al and Ga. The Gibbs free energy for H 2 binding, ΔG° bind (1 atm), to generate (η 2 -H 2 )HCoML was slightly more favorable for HCoGaL (-4.2(1) kcal/mol) than for HCoAlL (-2.7(1) kcal/mol). In the subsequent step, the deprotonation reaction to regenerate the initial catalyst was much more favorable for (η 2 -H 2 )HCoGaL (pK a of 31.4, CH 3 CN) than for (η 2 -H 2 )HCoAlL (pK a of 34.3). Finally, the straightforward substitution of Al with Ga perturbs the energy profile of the catalytic reaction (|ΔΔG° H– | = 5.4 kcal/mol, |ΔΔG° bind | = 1.5 kcal/mol, and |ΔΔG° K a | = 4.0 kcal/mol) and thus provides a thermodynamic rationale for the higher catalytic efficiency of Co–Ga over Co–Al.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Biphasic Janus Particles Explain Self-Healing in Pt–Pd Diesel Oxidation Catalysts

The addition of Pd to Pt-based diesel oxidation catalysts is known to enhance performance and restrict the anomalous growth of Pt nanoparticles when subjected to aging at high temperatures in oxidative environments. To gain a mechanistic understanding, we studied the transport of the mobile Pt and Pd species to the vapor phase, since vapor phase transport is the primary route for sintering in these catalysts. The results are surprising: there is a 30-fold drop in the effective vapor pressure of Pt in the Pt-Pd catalysts compared to monometallic Pt. At the same time, there is a significant enhancement in the vapor pressure of Pd, compared to PdO, which otherwise has a negligible vapor pressure at the aging temperature. Such behavior cannot be explained simply by alloying Pt and Pd in the metallic phase, or a core-shell morphology where a PdO shell covers a Pt core. Transmission electron microscopic examination of catalysts aged up to 50 h in air at 800 °C shows that the particles exhibit a biphasic “Janus”-like structure. The metal and oxide phases are conjoined, exposing a metal and an oxide face to the gas phase. The high mobility of the Pt and Pd allows them to be partitioned into the metal and oxide phases, in apparent thermodynamic equilibrium. The PdO helps to trap mobile PtO2 and as a result contains high concentrations of Pt oxide, consistent with its role in mitigating the transport of Pt to the vapor phase and preventing the growth of anomalously large particles. In turn, Pt allows Pd to remain metallic, allowing the catalyst to retain both metal and oxide functionality for catalysis. The regeneration of deactivated catalysts typically requires an external input, such as a change in the working environment from reducing to oxidizing or vice-versa. Here, we show that the mobile species, which are primary contributors to catalyst sintering are effectively returned to the active site, hence our use of the term “selfhealing”. The detailed insights into the inner workings of the Pt-Pd diesel oxidation catalysts can help provide clues to the design of robust and durable heterogeneous catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Highly selective cross ketonization of renewable acids over magnesium oxide

The rising demand for linear alkylbenzene surfactants (LAS) poses an environmental threat as LAS are industrially produced from petroleum using corrosive acid catalysts. Cross ketonization is a promising route of converting furans and fatty acids to oleo-furansulfonates, precursors for renewable, performance-enhanced LAS replacements. Here, we explore various alkaline earth metals and mixed metal oxides for the cross-ketonization reaction and find that MgO achieves ~90% yield by minimizing the decarboxylation side reaction. Here, we illustrate the role of molecular structure on the cross-ketonization reaction and the role of complex formation over alkaline-earth metal oxides in minimizing side reactions. We overcome catalyst deactivation by regeneration over multiple runs. This research demonstrates the effectiveness of heterogeneous catalysts for cross ketonization toward developing renewable surfactants.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Regeneration of Benzimidazole-Based Organohydrides Mediated by Ru Catalysts

Benzimidazole-based organohydrides (BIHs) are versatile hydride, electron, and proton donors in a variety of artificial photosynthetic systems for the generation of solar fuels. Currently, BIHs are often used in stoichiometric rather than catalytic processes. The catalytic regeneration of BIHs from their oxidized form (BI + ) is an urgent necessity in order to allow the development of recyclable systems and devices, but viable examples are scarce and require large overpotentials. Here, in this study, we report the electrocatalytic regeneration of a series of BIHs with varying hydricities, promoted by a ruthenium half-sandwich complex, [(HMB)Ru(bpy)(H)]+ (HMB = η 6 -C 6 Me 6 , bpy = 2,2′-bipyridine), in the presence of tributylammonium (HNBu 3 + ) as a proton source. This metal hydride was generated in situ from the 2e - reduction/protonation of the corresponding solvento-complex. In comparison to the direct cathodic reduction of BI + in the presence of HNBu 3 + , the use of this ruthenium catalyst allowed efficient regeneration of BIHs at less negative potentials, with Faradaic efficiencies up to 80% and significantly higher conversion yields due to the circumvention of the dimerization pathway and the stepwise reduction and protonation reactions. Finally, the thermodynamic challenges involved in the regeneration of very hydridic BIHs mediated by Ru hydride catalysts were examined.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Dehydra-decyclization of tetrahydrofurans to diene monomers over metal oxides

The dehydra-decyclization of tetrahydrofuran (THF) to butadiene was investigated over a series of metal oxide catalysts, where a common set of chemical pathways was identified. Alongside butadiene, propene is formed via a retro-Prins condensation as the main side product typically observed. Reaction occurred at similar temperatures on each of the oxides, but tetragonal zirconia (t-ZrO 2 ) and monoclinic zirconia (m-ZrO 2 ) were unique in showing high selectivity to butadiene (>90%). Near quantitative yields to butadiene could be achieved over t-ZrO 2 at 673 K and a WHSV of 0.93 g THF gcat –1 h –1 . Through contact time studies, butadiene is determined to be a primary product. Methyl-substituted THF gave only moderate increases in rates and the products showed minimal isomerization of the carbon backbone. The t-ZrO 2 catalyst was found to be relatively stable with time on stream, experiencing coking as a likely source of deactivation. Complete regeneration of the catalyst was demonstrated through calcination alone, allowing for multiple regenerations with no irreversible loss in activity or selectivity. Lastly, the catalytic activity of zirconia was found to be structure insensitive, with t-ZrO 2 and m-ZrO 2 exhibiting similar initial activities; however, m-ZrO 2 was observed to deactivate much more rapidly.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Mechanistic aspects of plasma-enhanced catalytic methane decomposition by time-resolved operando diffuse reflectance infrared Fourier transform spectroscopy

To study mechanistic aspects of plasma-enhanced catalysis, methane is decomposed by a supported Ni catalyst assisted by an Ar/O 2 atmospheric pressure plasma jet (APPJ). Here, the time-resolved surface response of the Ni catalyst is investigated by operando diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) using various experimental settings. Catalyst temperatures of room temperature (RT) and 500 °C and nozzle-catalyst surface distances of 3, 5 and 8 mm were examined, and the amount of O 2 of the Ar/O 2 gas mixture flowing through the APPJ was either 0 or 0.5%. A synergistic effect of surface bonded C-O was observed during the exposure of the Ni catalyst to the APPJ for low oxygen operating conditions (pure Ar jet). Surface bonded C-O formed only when there was plasma present and the C-O signal was enhanced for higher catalyst temperature. When the supported Ni catalyst was subjected to the plasma-generated particle fluxes using highly oxidizing conditions, the presence of surface bonded C-O was suppressed. The plasma-catalytic CO and CO 2 production in the gas phase measured downstream mirrored the surface behavior of C-O bonds when the plasma source operating condition was changed from a low oxygen portion to a high oxygen portion at high catalyst temperature (500 °C). CH n (n =1, 2, ) species on the catalyst surface were also studied by DRIFTS, and CHn destruction was found to correlate with C-O formation. In particular, the time-resolved CH n response showed a possible conversion process of CH n to C-O when the Ni catalyst was exposed to the plasma source. This finding may indicate a plasma-mediated regeneration of the catalyst by plasma-catalyst surface interactions.

42 ENGINEERING↗
DOE OSTI2024

Core-Shell Oxidative Aromatization Catalysts for Single Step Liquefaction of Distributed Shale Gas (Final Technical Report)

The objective of this project was to design and demonstrate a core-shell structured multifunctional catalyst to convert the light (dry) components of shale gas into liquid aromatic compounds (primarily benzene and toluene) in a single step. Operated in a modular oxidative aromatization system (OAS) under a cyclic redox scheme, the novel catalyst and process can significantly improve the value and transportability of distributed shale gas. Since the project started, each quarter addressed a different set of tasks related to the completion of the milestone detailed in the project award. The yearly summaries of these tasks are summarized below: Q1-Q4: • Conducted project planning and literature search. • Investigated a number of SHC redox catalysts using thermogravimetric analysis and fixed-bed reactor experiments. • Initiated process modeling towards generating two process models for the methane DHA base case and OAS process. • Developed DHA catalysts capable of producing >500 g/kg-cat-hr aromatics at 80% or greater aromatics selectivity at 700°C. Q5-Q8: • Developed alternative approaches with sequential bed configurations to enhance the aromatic yields based on OCM+DHA • Improved the zeolite synthesis efficiency by using the microwave-assisted technique and investigated the synthesis conditions on the zeolite yield, crystalline structure and morphology • Constructed a set of Aspen Plus process models with significant energy savings for OAS as compared to the base case non-oxidative DHA. • Adapted conventional hydrothermal method to be applicable to the microwave synthesizer unit for more efficient catalyst synthesis. • Studied the structure of the OCM catalyst and the dispersion of the carbonate in the redox reactions and in methane flow with Raman Spectroscopy. Q9-Q12: • Scaled up the catalyst synthesis with the microwave synthesis method. Based on its performance, procedural characterizations and catalytic performance testing were further conducted for the new microwave synthesized catalysts with the newly-developed product analysis procedure. • Developed the reaction system setup for the C2-DHA or OCM+DHA reaction product and achieved a better product collection-analysis method for the aromatic products with an improved carbon balance. The product from the OCM reaction exhibited complicated effects on the DHA catalyst. • Conducted additional OCM catalyst characterization using Near Ambient Pressure X-ray Photoelectron Spectroscopy and in situ Raman characterization • Validated the significant energy savings for OAS as compared to the base case non-oxidative DHA. Successfully set up the simulation model for the OCM+DHA+SHC reaction system based on the updated experimental results from NCSU. Q13-End of project: • Synthesized new zeolite catalysts by the microwave method, conducted characterizations (XRD, SEM, and TEM) and catalytic behavior testing. • Explored the “wet” C 2 H 6 and C 2 H 4 DHA reactions with using steam co-feed. A subsequent reduction as the regeneration step can regenerate the DHA catalyst and recover 99% activity of the fresh performance. • Achieved a 15.3% single-pass aromatic yield from methane by rationally combining the OCM and DHA at different temperatures. • Conducted a 105-hour stability test with an improved regeneration procedure, with an average aromatic yield of 13.8%. • Developed new catalyst and achieved a record-high 23.2% yield.

03 NATURAL GAS↗
DOE OSTI2020

Effect of Using Regenerated Combined FAU and MOR Zeolites as Catalysts during the Pyrolysis of Kraft Lignin

The SiO 2 /Al 2 O 3 mole ratio, pore size, and acid sites are the key parameters of zeolite’s activity in lignin pyrolysis. In this study, the comparison of individual Y and M zeolites, the combined ‘Y + M’ sample after regeneration, and their effect on lignin pyrolysis were studied in five cycles (regeneration and reuse). The results were explained using Brunauer, Emmet, and Teller (BET), micropore surface area (MSA), and total acid sites (TAS) analyses. In comparison with the individual Y or M zeolite sample, the consistent higher catalytic activities of the combined ‘Y + M’ sample in repeated cycles were observed. Pyrolysis heavy oils were characterized by nuclear magnetic resonance (NMR) spectroscopy and gel permeation chromatography (GPC). The NMR analyses revealed that with increased zeolite regeneration cycles, p-hydroxy phenyl and methoxyl groups increased. Decreases in guaiacyl phenolic hydroxyl were less for the combined ‘Y + M’ sample than the individual Y and M zeolites. Lower weight average (M w ) of heavy oil for the combined ‘Y + M’ sample indicated the enhanced cleavage of lignin structures in pyrolysis. These results support the higher catalytic activity of regenerated zeolites for the combined ‘Y + M’ sample compared with individual Y and M zeolites due to the improved MSA and TAS.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Carbon-Assisted, Continuous Syngas Production in a Chemical Looping Scheme

In the current energy and environment scenario, it is imperative to develop energy efficient routes for chemical manufacturing that also pave the way for mitigation of greenhouse gas emissions. This work presents an efficient pathway for continuous syngas production via a chemical looping conversion of the two most potent greenhouse gases—CH 4 , and CO 2 . The well-known dry-reforming process of converting CH 4 , and CO 2 to syngas is energy-intensive and suffers from catalyst deactivation. The chemical looping approach, on the other hand, provides avenues for mitigating catalyst deactivation and enabling improved energy efficiency. The key to such process enhancements lies in the intricate structure–function relationships of the catalyst and its correlation to the process variables. We present the reduction and oxidation characteristics of 5 wt.% Ni/Ce 1-x Zr x O 2 -based catalysts (x = 0, 0.4, and 0.625). We demonstrate low temperature CH4 activation over Ni-promoted samples as opposed to pure Ce 1-x Zr x O 2 . Moreover, our results depict an optimum regeneration of these catalysts when oxidized by CO 2 , and H 2 O, which allows for chemical looping operation of steam reforming of methane as well. Process variables were tuned to optimize the CH 4 conversion (over 80%), and H 2 /CO ratio at 650 °C. The critical surface reactions—carbon accumulation and gasification, and thermocatalytic CO 2 splitting were investigated to elucidate the dynamic nature of the catalyst surface. In conclusion, the impact of this work lies in showcasing the opportunities to design chemical looping reactors for energy efficient syngas production from waste greenhouse gases.

25 ENERGY STORAGE↗
DOE OSTI2025

Microwave-assisted pyrolysis of liquid hydrocarbons using iron-based alumina catalysts obtained by solution combustion synthesis: The effect of synthesis parameters

The microwave-absorbing and catalytic properties of iron-based alumina (FeAl x O y ) materials have enabled their use as catalysts for the microwave-assisted generation of hydrogen and carbon via pyrolysis of hydrocarbons. Solution combustion synthesis (SCS) is a promising method to fabricate these materials, but the pyrolysis performance still needs to be improved. The present work investigated how altering the SCS parameters affects the pyrolysis of diesel fuel, gasoline, and crude oil. Two fuels (citric acid and glycine), four Fe:Al molar ratios, and two heating modes (hotplate and furnace) were tested. Fe/γ-Al 2 O 3 and Fe/β-SiC catalysts were prepared via incipient wetness impregnation for comparison. Among the three fossil fuels tested, diesel fuel yielded the highest amounts of H 2 and least amounts of CO x . The choice of fuel for the SCS process and the Fe/Al ratio strongly affected pyrolysis performance as they influence properties important for both catalysis and microwave absorption. The use of glycine resulted in catalysts that exhibited high H 2 yield and low CO 2 generation, which is explained by the revealed structural differences. The increase in the Fe:Al molar ratio accelerated microwave heating by adding more magnetic loss but also increased the amount of CO x . When the optimal SCS parameters were used, FeAl x O y catalysts outperformed Fe/γ-Al 2 O 3 and Fe/β-SiC. The high H 2 generation efficiency of the SCS catalysts is explained by their enhanced microwave-absorption properties. Scanning electron microscopy and energy dispersive X-ray spectroscopy revealed the formation of large-diameter CNTs via the tip-growth mechanism. The regeneration of SCS catalysts was demonstrated via the Boudouard reaction.

Carbon nanotubes↗
DOE OSTI2023

Design and Operation of a Multi-Bed Catalytic Micro-Reactor for the Study of Co-Processing of Bio-Oils with VGO

An industry wide shift from fossil-based fuel to renewable fuel sources including biomass, municipal waste, and plastics will require new process monitoring methods to minimize transitional risks including off specification product formation and catalyst deactivation. This project aims to provide a machine learning based process monitoring tool composed of online, slipstream mass spectra for use in biomass refineries and co-processing in existing refineries allowing operators to monitor product qualities and adjust process conditions accordingly. In order to maximize the robustness of the tool, large volumes of data must be collected to fine tune model parameters which consists of both micro and pilot scale mass spectral data. Micro-scale data is collected with a multi-tube micro-reactor housing up to six catalysts in horizontal beds, coupled with a molecular beam mass spectrometer. A pyrolizer equipped with an auto-sampler streamlines the micro-scale data collection process. This type of pyrolizer/micro-reactor configuration does not exist on the market, and therefore had to be created for the purposes of this project. The design and commissioning of this reactor will be presented in detail. This reactor set-up is highly flexible and increases throughput of analysis. For catalyst testing, each bed can be individually selected simply by turning valves. For catalyst reduction and regeneration, simultaneous flow through all six beds is used. The reproducibility of the system was first assessed with whole biomass pyrolysis along with pyrolysis of calibration standards. Initial work on this system evaluated two FCC catalysts, equilibrium catalyst (E-cat), and a proprietary catalyst from Johnson Matthey specifically design for co-processing of bio-oil with vacuum gas oil (VGO). This work used model compounds and VGO which illuminated differences in products produced by the catalysts.

biomass↗
DOE OSTI2020

Production of renewable alcohols from maple wood using supercritical methanol hydrodeoxygenation in a semi-continuous flowthrough reactor

Biomass conversion to alcohols using supercritical methanol depolymerization and hydrodeoxygenation (SCM-DHO) with CuMgAl mixed metal oxide is a promising process for biofuel production. Here, we demonstrate how maple wood can be converted at high weight loadings and product concentrations in a batch and a semi-continuous reactor to a mixture of C 2 –C 10 linear and cyclic alcohols. Maple wood was solubilized semi-continuously in supercritical methanol and then converted to a mixture of C 2 –C 9 alcohols and aromatics over a packed bed of CuMgAlO x catalyst. Up to 95 wt% of maple wood can be solubilized in the methanol by using four temperature holds at 190, 230, 300, and 330 °C. Lignin was solubilized at 190 and 230 °C to a mixture of monomers, dimers, and trimers while hemicellulose and cellulose solubilized at 300 and 330 °C to a mixture of oligomeric sugars and liquefaction products. The hemicellulose, cellulose, and lignin were converted to C 2 –C 10 alcohol fuel precursors over a packed bed of CuMgAlO x catalyst with 70–80% carbon yield of the entire maple wood. The methanol reforming activity of the catalyst decreased by 25% over four beds of biomass, which corresponds to 5 turnovers for the catalyst, but was regenerable after calcination and reduction. In batch reactions, maple wood was converted at 10 wt% in methanol with 93% carbon yield to liquid products. The product concentration can be increased to 20 wt% by partially replacing the methanol with liquid products. The yield of alcohols in the semi-continuous reactor was approximately 30% lower than in batch reactions likely due to degradation of lignin and cellulose during solubilization. These results show that solubilization of whole biomass can be separated from catalytic conversion of the intermediates while still achieving a high yield of products. However, close contact of the catalyst and the biomass during solubilization is critical to achieve the highest yields and concentration of products.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Redistribution of Ru in Fe 2 O 3 –Ru Nanocatalysts through an Oxidative Pretreatment Improves Reverse Water–Gas Shift Activity

We have synthesized Fe–Ru nanoparticles via a solvothermal method to create catalysts for the reverse water–gas shift reaction and demonstrated the impact of reductive and oxidative pretreatments on both catalytic performance and structure. Catalytic testing showed improved activity after exposure to O 2 at 600 °C. In contrast, the activity became lower if then exposed to H 2 at 600 °C. Environmental scanning transmission electron microscopy and scanning electron microscopy showed that exposure to O 2 at 600 °C changes the morphology and completely oxidizes Fe into Fe 2 O 3 . Exposure to H 2 at elevated temperature caused Ru coalescence at the surface of the nanoparticle, forming clusters which decreased the optimization of Ru. Reoxidation of the particles exposed to H 2 , however, caused a redistribution of Ru that appears beneficial in maximizing Ru exposure and synergy with Fe oxide, with no major changes in the morphology and oxide structure. Furthermore, our diagnostics demonstrate the complex and reversible rearrangements possible in these multicomponent particles and the benefits of oxidative pretreatment to enhance or regenerate Fe–Ru catalysts in other important catalytic reactions such as Fischer–Tropsch synthesis.

Fe−Ru nanoparticles↗
DOE OSTI2021

Atomically Dispersed Tin-Modified $\gamma$-alumina for Selective Propane Dehydrogenation under H 2 S Co-feed

Developing an earth-abundant catalyst that is sulfur-tolerant, active, and highly selective is of great interest for valorizing natural gas streams containing sour gas. Here, a tin-modified alumina catalyst is reported that is stable and selective for propane dehydrogenation in the presence of percent quantities of H 2 S in the feed. In particular, Sn/Al 2 O 3 –S catalysts with 1.5–5% Sn content exhibit 98% selectivity with up to 16% conversion at 560 °C during the fourth cycle. Experimental and computational characterization shows that the active sites are the defect tricoordinated Al atoms. H 2 S pretreatment further modifies a portion of these sites via exchanging a neighboring oxygen atom with sulfur, thereby rendering them more active and selective. At low loadings, Sn is atomically dispersed and selectively binds to hydroxyl groups or oxygen atoms on Al 2 O 3 . This prevents the formation of original (unmodified) defect sites on Al 2 O 3 and improves overall selectivity. The activity and selectivity of the catalyst are heavily dependent on the chemical potential of sulfur and hydrogen because they influence both the relative concentration of the two types of sites and the overall reaction mechanism. Finally, the catalyst can be regenerated fully under a pure H 2 S stream, thereby precluding treatment under oxygen, which can lead to sintering.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Electromagnetic Energy-Assisted Thermal Conversion of Fossil-Based Hydrocarbons to Low-Cost Hydrogen

The goal of this project was to develop and optimize catalysts for methane decomposition, particularly focusing on regeneration via an electromagnetic energy-assisted mechanism, to produce hydrogen more cost-effectively compared to electrolysis routes. To achieve this goal, the project pursued several key objectives. The project began with the preparation and testing of various catalysts. A nickel-silica based catalyst was identified as the most promising material for the pyrolysis of methane into carbon and hydrogen. Kinetic parameters for methane decomposition were determined, aiding in computational modeling efforts. Structured catalysts were investigated, highlighting the need for frequent cleaning or regeneration to maintain performance, with methane conversion rates exceeding 70% in tube furnace tests. Computational fluid dynamics modeling was employed to optimize reactor designs and electrode angles, leading the project team to propose a multi-compartment thermal conversion system for larger setups. This modeling work was important in understanding reaction characteristics, carbon deposition rates, and temperature profiles under various conditions. A bench-scale reactor system was assembled to evaluate catalyst regeneration using electromagnetic energy-assisted mechanisms. Experiments demonstrated the potential for carbon removal, though further optimization is needed. The carbon produced from the methane conversion process was evaluated for potential use in lithium-ion battery electrodes. The carbon exhibited properties similar to commercially available high-purity multi-walled carbon nanotubes and nanofibers, with a carbon content greater than 95%. Coin cell batteries assembled with this carbon showed that lower replacement levels (10% to 33%) outperformed the control group, improving specific capacity density and stability. However, higher replacement levels (100%) demonstrated poorer performance, suggesting that excessive carbon substitution negatively impacts battery performance. These findings indicate the potential marketability of the produced carbon as a component in lithium-ion batteries, though further testing is necessary to confirm long-term advantages and disadvantages associated with the use of the carbon product. These results however justified further technoeconomic assessments to determine if the process can provide low-cost hydrogen. The economic feasibility and technical performance of methane decomposition for hydrogen production were assessed, focusing on three plant configurations: 100E (electrically heated), 100C (combustion heated using produced hydrogen), and PE-Hybrid (a combination of pyrolysis (indicating decomposition) and electrolysis). The Levelized Cost of Hydrogen (LCOH) for the pyrolysis configurations was found to be approximately 25% lower than that of electrolysis. The 100E configuration had the lowest LCOH at $\$$3.12/kg. Including carbon product sales significantly improved the economics, with the 100C configuration achieving a negative LCOH of -$\$$0.35/kg. The PE-Hybrid configuration was not economically advantageous compared to pure pyrolysis plants due to its complexity and additional equipment requirements. Ultimately, methane pyrolysis presents a viable method for near carbon dioxide-free hydrogen production, with significant economic advantages over electrolysis, especially when considering the sale of carbon byproducts. The 100E and 100C configurations showed the most promise, with the choice between them ultimately depending on the prices of power and natural gas. In conclusion, this technology has the potential to lower hydrogen production costs by leveraging the methane decomposition process with the sale of valuable carbon byproducts. By optimizing catalyst performance and integrating electromagnetic energy-assisted regeneration, the process can achieve higher efficiency and economic viability, making it a competitive alternative to traditional hydrogen production methods.

08 HYDROGEN↗
DOE OSTI2020

Catalytic Bio-crude Production in a Novel, Short-Contact Time Reactor

RTI has developed a catalytic fast pyrolysis (CFP) process to produce biomass-based hydrocarbon replacement fuels. From a technology perspective, this advanced biofuels process produces liquid transportation fuels that can leverage capital expenditures in the existing petroleum distribution infrastructure. From a business perspective, this technology does not face potential market limitations caused by oxygenate blend limitations for light duty vehicle applications. A promising catalyst has been developed with excellent potential for deoxygenation to produce a hydrocarbon-rich biocrude that is more suitable for upgrading with traditional hydroprocessing technology. The role of the catalyst is to control the chemistry during biomass pyrolysis to produce a biocrude in a single step that has lower oxygen content and is more thermally stable than conventional biomass fast pyrolysis oil. Catalyst properties are optimized to minimize gas and coke production and improve catalytic deoxygenation and biocrude yields. Results from this project have demonstrated that biocrudes from catalytic fast pyrolysis contain <20 wt% oxygen, with the organic fraction as low as 12% oxygen. These oxygen numbers are > 50% lower compared to traditional fast pyrolysis oils. The biocrude produced from our CFP process can be upgraded to gasoline range hydrocarbons. A very conservative approach for upgrading included a preliminary stabilization step followed by a hydroprocessing step. The oxygen content in the upgraded product was decreased by 97% (to less than 3wt %) from the oxygen content of the biocrude sample. Additionally, the acid content was reduced by 99% from the acid content of the biocrude sample. In an optimized integrated process, the CFP step and the hydroprocessing (upgrading) step need to be carefully balanced to maximize the input biomass energy that is recovered in the finished biofuels. Hydrogen utilization and carbon recovery during both catalytic biomass pyrolysis and biocrude upgrading need to be optimized to maximize energy recovery in the finished biofuel. A nominal 1 ton per day (TPD) catalytic biomass pyrolysis system was designed based on the laboratory experimental data. The system was designed to achieve the short residence times (0.5–2 sec) and high heat transfer rates required for maximum liquid biocrude yields while optimizing process integration to maintain catalyst activity by continuous regeneration. The catalytic biomass pyrolysis reactor is a continuously circulating single-loop transport reactor design that is flexible enough to allow sensitivity studies around temperature, residence time, biomass feed rate, and catalyst-to-biomass ratio (i.e., catalyst circulation rate) for process optimization. For a nominal 100 lb/hr feed rate of dry biomass, the products include ~25 lb/hr char and coke, ~20 lb/hr permanent gases, and ~55 lb/hr condensable vapors. Pyrolysis temperatures are 350–600°C, and the system is operated close to ambient pressure. Production of the catalyst developed within the project was scaled up to provide enough material (200kg) for bench-scale testing. The 1TPD bench-scale unit was fabricated, installed and commissioned with this project. Biocrude samples from wood were produced in this unit with the CFP catalyst with material balance > 90%. The intermediate biocrude yields and chemical composition compare well with previous laboratory results and a hydroprocessing strategy for upgrading the resulting biocrude was developed. The experimental results obtained within this project were used to develop a process model for a 2000 TPD commercial facility. Detailed flow sheets were developed for all major unit operations in the process and provided a basis for an economic analysis to develop capital and operating costs. Estimates of the biofuel production costs were used to develop internal rates of return for the yields and compositions measured for the current state of technology at the end of this project and for the yields anticipated for an optimized (nth plant) scenario as additional process improvements are made.

09 BIOMASS FUELS↗