SUSTEON INC — Department of Energy SBIR Phase I: 31c

Description

The proposed project aims at understanding of plasma/catalyst interaction using a commercially scalable plasma reactor design. If successful, this technology will enable utilization of two major greenhouse gases CH4 and CO2, both are highly stable and require high temperatures (>900°C) to produce products like H2, methanol, syngas, jet fuel, olefins, etc., which have a high carbon footprint. Furthermore, this technology can be extended to produce NH3 as a potential carrier for H2 by activating nitrogen by this process. The energy source for these reactions would be renewable power produced from solar, wind and other renewable resources. We propose to study low-temperature plasma catalysis involving plasma reactivity and catalyst selectivity using the steam methane reform (SMR) reaction as a surrogate. The understanding and insights gained in this study could have wide applicability to other industrially important reactions such as ammonia production, methane dry reforming with CO2, alkane oxidative dehydrogenation, etc. We will study the SMR reaction in a commercially scalable Catalytic Low Temperature Plasma (CLTP) reactor at a scale of 1 kg/day H2 production rate. Preliminary laboratory data suggest CH4 conversion is more than 90% with greater than 70% H2 in the product gas. Modular CLTP technology offers many advantages: high CH4 conversion and high H2 selectivity, high thermal efficiency, ~30% lower CO2 footprint with potential for complete CO2 capture, wide turndown ratio, short and multiple stop/starts capability with on-demand operation. This process converts methane into a hydrogen-rich syngas using a Ni nanoparticle coated tubular reactor in a low temperature, dielectric barrier discharge (DBD) plasma environment. Here, we are leveraging two key innovations; (1) adaptation of commercial low temperature plasma reactor design used in ozone generation for methane reforming, and (2) wash coating of the Ni nanoparticle catalyst inside the reactor tube wall. We propose to demonstrate stable plasma catalytic system capable of greater than 90% CH4 conversion in Phase I. To achieve this goal, we will (1) design and build a CLTP reactor, (2) evaluate CH4 conversion efficiency with a commercial Ni/Al2O3 catalyst under different conditions, (3) optimize plasma power and reactor operating conditions for stable performance, and (4) perform a preliminary techno-economic analysis to evaluate the commercial potential of this process. In Phase II, at least five units of 1 kg/day H2 will be integrated to make a prototype commercial hydrogen generator producing ≥ 5 kg/day. It will be tested to obtain engineering data for design and construction of a 100 kg H2/day distributed scale hydrogen. Electrification of chemical processes using renewable power is a technically viable pathway for decarbonization of chemical industry. Our novel catalytic low temperature plasma (CLTP) system offers a promising technology platform for high performance, electrified, and low emission intensification of various industrially relevant processes like steam methane reforming, CO2 activation, ammonia production etc. We demonstrate steam methane reforming as a model reaction for CLTP. The novel process is expected to produce hydrogen at market competitive prices along with a pure stream of CO2 ready for utilization.