High-temperature kinetics of the homogeneous reverse water-gas shift reaction

A Carbon Capture and Utilization Process for the Production of Solid Carbon Materials from Atmospheric CO2 - Part 1: Process Performance

The successful operation of a process that converts atmospheric CO2 into solid carbon products is presented as an alternative to fossil based solid carbon production. In a first step, CO2 is removed from the atmosphere by a direct air capture (DAC) unit. The gas is then mixed with hydrogen and enters a methanation unit. Depending on the operation conditions, gas mixtures consisting of mainly methane with either H2 or CO2 as side-component are obtained. After precipitating the water formed during the methanation step, the remaining gas mixture is fed into a bubble column reactor filled with liquid tin. During the rise of the gas bubbles, methane is thermally split up into hydrogen and solid carbon. The latter is continuously removed from the liquid metal surface as a fine powder by pneumatic conveying. This article is the first of two articles, focusing on the performance of the methanation and methane pyrolysis steps. The experimental results are complemented by thermodynamic analyses and reaction modelling. A detailed analysis of the solid carbon product of the process is presented in the second part.

Reaction Dynamics of CO2 Hydrogenation on Iron Catalysts Using ReaxFF Molecular Dynamics Simulation

The conversion of CO2 to hydrocarbons using catalysts is a promising route to utilize CO2 and produce more valuable chemicals in a sustainable manner. Recent studies have shown that iron-based catalysts perform well for the hydrogenation of CO2. While the hydrogenation reaction mechanism in the gas phase is straightforward, when catalyzed by iron it has been demonstrated to involve various chemical transformations, and the selectivity and conversion are strongly dependent on the particle size. To further investigate the dependence of the reactivity of iron catalysts on cluster size, we performed reactive molecular dynamics simulations using the ReaxFF force field (ReaxFF-MD) for iron nanoclusters of various sizes in a CO2 and H2-rich environment. We demonstrated that the homogeneous hydrogenation of CO2 was correctly described by this ReaxFF model. The dissociation mechanism of CO2 on the Fe4, Fe16 clusters, and the bcc(100) Fe slab agrees with previous DFT results. The ReaxFF-MD simulations suggest a strong dependence of reactivity on the cluster size, with the Fe4 cluster having the highest reactivity. We show that ReaxFF-MD provides a route to understand reaction mechanisms in these nonequilibrium reactive processes where fast processes and local minima are important.

Self-Oxidation of the Atmospheres of Rocky Planets with Implications for the Origin of Life

Rocky planets may acquire a primordial atmosphere by the outgassing of volatiles from their magma ocean. The distribution of O between H2O, CO, and CO2 in chemical equilibrium subsequently changes significantly with decreasing temperature. We consider here two chemical models: one where CH4 and NH3 are assumed to be irrevocably destroyed by photolysis and second where these molecules persist. In the first case, we show that CO cannot coexist with H2O, since CO oxidizes at low temperatures to form CO2 and H2. In both cases, H escapes from the thermosphere within a few 10 million years by absorption of stellar XUV radiation. This escape drives an atmospheric self-oxidation process, whereby rocky planet atmospheres become dominated by CO2 and H2O regardless of their initial oxidation state at outgassing. HCN is considered a potential precursor of prebiotic compounds and RNA. Oxidizing atmospheres are inefficient at producing HCN by lightning. Alternatively, we have demonstrated that lightning-produced NO, which dissolves as nitrate in oceans, and interplanetary dust particles may be the main sources of fixed nitrogen in emerging biospheres. Our results highlight the need for origin-of-life scenarios where the first metabolism fixes its C from CO2, rather than from HCN and CO.

CO2 Electrolyzers

CO2 electrolyzers have progressed rapidly in energy efficiency and catalyst selectivity toward valuable chemical feedstocks and fuels, such as syngas, ethylene, ethanol, and methane. However, each component within these complex systems influences the overall performance, and the further advances needed to realize commercialization will require an approach that considers the whole process, with the electrochemical cell at the center. Beyond the cell boundaries, the electrolyzer must integrate with upstream CO2 feeds and downstream separation processes in a way that minimizes overall product energy intensity and presents viable use cases. Here we begin by describing upstream CO2 sources, their energy intensities, and impurities. We then focus on the cell, the most common CO2 electrolyzer system architectures, and each component within these systems. We evaluate the energy savings and the feasibility of alternative approaches including integration with CO2 capture, direct conversion of flue gas and two-step conversion via carbon monoxide. We evaluate pathways that minimize downstream separations and produce concentrated streams compatible with existing sectors. Applying this comprehensive upstream-to-downstream approach, we highlight the most promising routes, and outlook, for electrochemical CO2 reduction.

Effect of Weathering on Steel Converter Slag Used as an Oxygen Carrier

Steel converter slag, also called LD slag, is a material that has been suggested for use as a low-cost oxygen carrier for chemical looping applications. Low-cost oxygen carriers are especially relevant for the conversion of solid fuels, which may contain large amounts of reactive ashes. Ash may limit the lifetime of the bed material, which is why a high-cost oxygen carrier will likely not be competitive. Applying LD slag on an industrial scale as an oxygen carrier makes the storage properties of the material highly interesting. LD slag has been known to be affected by weathering, thus limiting the possibilities of the material to be used in construction, e.g., as fillers in concrete. In this study, pretreated LD slag for use as an oxygen carrier was weathered outdoors for roughly 1.5 years in southwest Sweden. Afterward, the particles were characterized and used in a laboratory batch fluidized bed reactor system to evaluate the effects of storage on the oxygen carrier properties. It was found that the reactivity with the fuel of the weathered LD slag was similar to that of the original sample when used in a laboratory fluidized bed. However, the physical properties were severely degraded due to weathering. Dissolved CaO formed CaCO3, agglomerating the top layer of the sample. The particles in the bulk of the sample were found to have decreased density and increased attrition rate. This suggests that LD slag particles for use as oxygen carriers should be stored dry to avoid weathering of the particles.

Highly Active and Stable Ni/La-Doped Ceria Material for Catalytic CO2 Reduction by Reverse Water-Gas Shift Reaction

The design of an active, effective, and economically viable catalyst for CO₂ conversion into value-added products is crucial in the fight against global warming and energy demand. We have developed very efficient catalysts for reverse water-gas shift (rWGS) reaction. Specific conditions of the synthesis by combustion allow the obtention of macroporous materials based on nanosized Ni particles supported on a mixed oxide of high purity and crystallinity. Here, we show that Ni/La-doped CeO₂ catalysts─with the "right" Ni and La proportions─have an unprecedented catalytic performance per unit mass of catalyst for the rWGS reaction as the first step toward CO₂ valorization. Correlations between physicochemical properties and catalytic activity, obtained using a combination of different techniques such as X-ray and neutron powder diffraction, Raman spectroscopy, in situ near ambient pressure X-ray photoelectron spectroscopy, electron microscopy, and catalytic testing, point out to optimum values for the Ni loading and the La proportion. Density functional theory calculations of elementary steps of the reaction on model Ni/ceria catalysts aid toward the microscopic understanding of the nature of the active sites. This finding offers a fundamental basis for developing economical catalysts that can be effectively used for CO₂ reduction with hydrogen. A catalyst based on Ni_0.07/(Ce_0.9La_0.1O_x)_0.93 shows a CO production of 58 × 10^-5 mol_CO·g_cat^-1·s^-1 (700 °C, H₂/CO₂ = 2; selectivity to CO > 99.5), being stable for 100 h under continuous reaction.

Simulation and Optimization of a Multistage Interconnected Fluidized Bed Reactor for Coal Chemical Looping Combustion

This work established a three-dimensional model of a chemical looping system with multistage reactors coupled with hydrodynamics and chemical reactions. The thermal characteristics in the chemical looping combustion (CLC) system were simulated using coal as fuel and hematite as an oxygen carrier (OC). Some significant aspects, including gas composition, particle residence time, backmixing rate, wall erosion, carbon capture rate, etc., were investigated in the simulation. Owing to the optimization by adding baffles in the fuel reactor (FR), the gas conversion capacity of the multistage FR was high, where the outlet CO₂ concentration was as high as 93.8% and the oxygen demand was as low as 3.8%. Through tracing and analyzing the path of char particles, we found that the residence time of most char particles was too short to be fully gasified. The residual char will be entrained into the air reactor (AR), reducing the CO₂ capture rate, which is only 80.3%. In the simulation, the wall erosion on the cyclone could be relieved by increasing the height of the horizontal pipe. In addition, improving the structure of the AR loop seal could control the residual char entrained by OC particles to the AR, and the CO₂ capture rate was increased up to 90% in the multistage CLC reactor.

Highly Active CuOx/SiO2 Dot Core/Rod Shell Catalysts with Enhanced Stability for the Reverse Water Gas Shift Reaction

Cu-based catalysts are highly active and selective for several CO₂ conversion reactions; however, traditional monometallic Cu-based catalysts suffer poor thermal stability due to the aggregation of copper particles at high temperatures. In this work, we demonstrate a crystal engineering strategy to controllably prepare copper/silica (CuO_x/SiO₂) catalysts for the reverse water gas shift reaction (RWGS) at high temperatures. We show that CuO_x/SiO₂ catalysts derived from the in situ reduction of pure copper silicate nanotubes in a CO₂ and H₂ atmosphere exhibit superior catalytic activity with enhanced stability compared to traditional monometallic Cu-based catalysts for the RWGS at high temperatures. Detailed structural characterization reveals that there is a strong interaction between Cu and SiO₂ in CuO_x/SiO₂ catalysts, which produces more Cu⁺ sites and smaller CuO_x nanoparticles. Moreover, CuO_x/SiO₂ catalysts possess a unique dot core/rod shell structure, which could prevent the aggregation of Cu particles. This structural confinement effect, enhanced CO₂ adsorption by Cu⁺, and small CuO_x nanoparticles presumably caused the catalyst's extraordinary activity with enhanced stability at high temperatures.

Impact of Carbon Dioxide on the Non-Catalytic Thermal Decomposition of Methane

Economically and ecologically, the thermal decomposition of methane is a promising process for large scale hydrogen production. In this experimental study, the non-catalytic decomposition of methane in the presence of small amounts of carbon dioxide was analyzed. At large scales, natural gas or biomethane are possible feedstocks for the thermal decomposition and can obtain up to 5% carbon dioxide. Gas recycling can increase the amount of secondary components even further. Experiments were conducted in a packed flow reactor at temperatures from 1250 to 1350 K. The residence time and the amounts of carbon dioxide and hydrogen in the feed were varied. A methane conversion of up to 55.4% and a carbon dioxide conversion of up to 44.1% were observed. At 1300 K the hydrogen yield was 95% for a feed of methane diluted in nitrogen. If carbon dioxide was added to the feed at up to a tenth with regard to the amount of supplied methane, the hydrogen yield was reduced to 85%. Hydrogen in the feed decreases the reaction rate of the methane decomposition and increases the carbon dioxide conversion.

Process Integration of Green Hydrogen: Decarbonization of Chemical Industries

Integrated water electrolysis is a core principle of new process configurations for decarbonized heavy industries. Water electrolysis generates H2 and O2 and involves an exchange of thermal energy. In this manuscript, we investigate specific traditional heavy industrial processes that have previously been performed in nitrogen-rich air environments. We show that the individual process streams may be holistically integrated to establish new decarbonized industrial processes. In new process configurations, CO2 capture is facilitated by avoiding inert gases in reactant streams. The primary energy required to drive electrolysis may be obtained from emerging renewable power sources (wind, solar, etc.) which have enjoyed substantial industrial development and cost reductions over the last decade. The new industrial designs uniquely harmonize the intermittency of renewable energy, allowing chemical energy storage. We show that fully integrated electrolysis promotes the viability of decarbonized industrial processes. Specifically, new process designs uniquely exploit intermittent renewable energy for CO2 conversion, enabling thermal integration, H2 and O2 utilization, and sub-process harmonization for economic feasibility. The new designs are increasingly viable for decarbonizing ferric iron reduction, municipal waste incineration, biomass gasification, fermentation, pulp production, biogas upgrading, and calcination, and are an essential step forward in reducing anthropogenic CO2 emissions.

Modeling of Laboratory Steam Methane Reforming and CO2 Methanation Reactors

To support the interpretation of the experimental results obtained from two laboratory-scale reactors, one working in the steam methane reforming (SMR) mode, and the other in the CO2 hydrogenation (MCO2) mode, a steady-state pseudo-homogeneous 1D non-isothermal packed-bed reactor model is developed, embedding the classical Xu and Froment local kinetics. The laboratory reactors are operated with three different catalysts, two commercial and one homemade. The simulation model makes it possible to identify and account for thermal effects occurring inside the catalytic zone of the reactor and along the exit line. The model is intended to guide the development of small size SMR and MCO2 reactors in the context of Power-to-X (P2X) studies.

Activity of La0.75Sr0.25Cr0.5Mn0.5O3−δ, Ni3Sn2 and Gd-doped CeO2 towards the reverse water-gas shift reaction and carburisation for a high-temperature H2O/CO2 co-electrolysis

LSCrM_, Ni₃Sn₂ and GDC₂₀ powders show high activity and selectivity for the RWGS reaction.

Combined Steam Reforming of Methane and Formic Acid To Produce Syngas with an Adjustable H2:CO Ratio

Syngas is an important intermediate in the chemical process industry. It is used for the production of hydrocarbons, acetic acid, oxo-alcohols, and other chemicals. Depending on the target product and stoichiometry of the reaction, an optimum (molar) ratio between hydrogen and carbon monoxide (H₂:CO) in the syngas is required. Different technologies are available to control the H₂:CO molar ratio in the syngas. The combination of steam reforming of methane (SRM) and the water-gas shift (WGS) reaction is the most established approach for syngas production. In this work, to adjust the H₂:CO ratio, we have considered formic acid (FA) as a source for both hydrogen and carbon monoxide. Using thermochemical equilibrium calculations, we show that the syngas composition can be controlled by cofeeding formic acid into the SRM process. The H₂:CO molar ratio can be adjusted to a value between one and three by adjusting the concentration of FA in the reaction feed. At steam reforming conditions, typically above 900 K, FA can decompose to water and carbon monoxide and/or to hydrogen and carbon dioxide. Our results show that cofeeding FA into the SRM process can adjust the H₂:CO molar ratio in a single step. This can potentially be an alternative to the WGS process.

Metal-Organic-Framework-Mediated Nitrogen-Doped Carbon for CO2 Electrochemical Reduction

A nitrogen-doped carbon was synthesized through the pyrolysis of the well-known metal-organic framework ZIF-8, followed by a subsequent acid treatment, and has been applied as a catalyst in the electrochemical reduction of carbon dioxide. The resulting electrode shows Faradaic efficiencies to carbon monoxide as high as ∼78%, with hydrogen being the only byproduct. The pyrolysis temperature determines the amount and the accessibility of N species in the carbon electrode, in which pyridinic-N and quaternary-N species play key roles in the selective formation of carbon monoxide.

Hydrogen-assisted Carbon Dioxide Thermochemical Reduction on La0.9 Ca0.1 FeO3-δ Membranes: A Kinetics Study

Kinetics data for CO₂ thermochemical reduction in an isothermal membrane reactor is required to identify the rate-limiting steps. A detailed reaction kinetics study on this process supported by an La_0.9 Ca_0.1 FeO_3-δ (LCF-91) membrane is thus reported. The dependence of CO₂ reduction rate on various operating conditions is examined, such as CO₂ concentration on the feed side, fuel concentrations on the sweep side, and temperatures. The CO₂ reduction rate is proportional to the oxygen flux across the membrane, and the measured maximum fluxes are 0.191 and 0.164 μmol cm^-2  s^-1 with 9.5 mol% H₂ and 11.6 mol% CO on the sweep side at 990 °C, respectively. Fuel is used to maintain the chemical potential gradient across the membrane and CO is used to derive the surface reaction kinetics. This membrane also exhibits stable performances for 106 h. A resistance-network model is developed to describe the oxygen transport process and the kinetics data are parameterized using the experimental values. The model shows a transition of the rate limiting step between the surface reactions on the feed side and the sweep side depending on the operating conditions.

Sustainable Conversion of Carbon Dioxide: An Integrated Review of Catalysis and Life Cycle Assessment

CO₂ conversion covers a wide range of possible application areas from fuels to bulk and commodity chemicals and even to specialty products with biological activity such as pharmaceuticals. In the present review, we discuss selected examples in these areas in a combined analysis of the state-of-the-art of synthetic methodologies and processes with their life cycle assessment. Thereby, we attempted to assess the potential to reduce the environmental footprint in these application fields relative to the current petrochemical value chain. This analysis and discussion differs significantly from a viewpoint on CO₂ utilization as a measure for global CO₂ mitigation. Whereas the latter focuses on reducing the end-of-pipe problem "CO₂ emissions" from todays' industries, the approach taken here tries to identify opportunities by exploiting a novel feedstock that avoids the utilization of fossil resource in transition toward more sustainable future production. Thus, the motivation to develop CO₂-based chemistry does not depend primarily on the absolute amount of CO₂ emissions that can be remediated by a single technology. Rather, CO₂-based chemistry is stimulated by the significance of the relative improvement in carbon balance and other critical factors defining the environmental impact of chemical production in all relevant sectors in accord with the principles of green chemistry.

Transient behavior of devolatilization and char reaction during steam gasification of biomass

Steam gasification of biomass is a promising method for producing high quality syngas for polygeneration. During the steam gasification, devolatilization and char reaction are key steps of syngas production and the contributions of the two reactions are highly related to gasification conditions. In this study, the transient characteristics of devolatilization and char reaction in biomass steam gasification were investigated by monitoring cumulative gas production and composition changes in terms of reaction temperature and S/B ratio. Contribution of each reaction stage on the product gas yield was studied in detail. The results provide important insight for understanding the complex nature of biomass gasification and will guide future improvements to the biomass gasification process.

Heat and Mass Transfer in Reduction Zone of Sponge Iron Reactor

Numerical prediction is performed on reduction zone of iron ore reactor which is a part of counter current gas-solid reactor for producing sponge iron. The aim of the present study is to investigate the effect of reduction gas composition and temperature on quality and capacity of sponge iron products through mathematical modeling arrangement and simulation. Simultaneous mass and energy balances along the reactor lead to a set of ordinary differential equation which includes kinetic equations. Kinetic equations of reduction of hematite to iron metal, methane reforming, and water gas shift reaction are taken into account in the model. Hydrogen and carbon monoxide are used as reduction gas. The equations were solved by finite element method. Prediction shows an increase in H2 composition while an attenuation of CO produces higher metallization degree. Metallization degree is also increased with an increase in gas inlet temperature. It is found that reduction gas temperature over 973°C (1246 K) is not recommended because the formation of sticky iron will be initiated.