Development of Allothermal Rotary Gasifier with CO2 Acceptor for Hydrogen Production from Coal Waste and Biomass
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09 BIOMASS FUELS↗
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Reduced hydrogen permeability at high temperatures
CO and CO2 reduce hydrogen loss through iron, nickel, and cobalt based alloy tubes. Method is based on concept that oxide film on metal surface reduces hydrogen permeability through metal; adding CO or CO2 forms oxide films continuously during operation, and hydrogen containment is improved. Innovation enhances prospects for Stirling engine system utilization.
Stephens, J. R.↗
Fabrication of a glycerol from CO2 reaction system, supplement
The fabrication, installation, and testing of a glycerol hydrogenation and a CO2 hydrogenation - CH4 partial oxidation units are reported. The glycerol system proved to be operational while the CO2 system was installed but not bought on operational steam.
Weiss, A. H.↗
Regularity in the correlation between the true urine reaction and the alveolar CO2 tension
Hydrogen ion concentration fluctuations in urine, and correlation with simultaneously measured carbon dioxide tension in arterial blood
ARTERY↗
Preliminary techno-economic assessment of gas switching reforming (GSR) of natural gas for pure hydrogen production and power generation with integrated CO2 capture
The increasing demand for hydrogen and the CO2 intensity of natural gas (NG) reforming motivate the development of low-carbon-emission hydrogen production technologies. Gas Switching Reforming (GSR) with integrated CO2 capture, a technology based on Chemical Looping Reforming (CLR), has been experimentally proven and shows potential for scale-up. In this study, select oxygen carriers (OC) (NiO/Al2O3, Fe2O3-CeO2/Al2O3, and magnetite) were tested in methane steam reforming in a fixed bed reactor to determine their relative reactivities under relevant conditions for GSR (800 °C, 7 bar total pressure). Process models were then developed to perform techno-economic analysis (TEA) of GSR for hydrogen production (GSR-H2) and a combined cycle (GSR-CC) in which high-purity H2 is fired in a gas turbine to produce electricity. Operating at 10 bar and 1100 °C and with the additional recovery steps implemented increased H2 production by ∼ 30% and improved efficiency relative to prior studies. For GSR-H2, the levelized cost of hydrogen (LCOH) is 1.61–1.64 $/kg-H2, competitive with a reference SMR case, though operating and maintenance costs are higher due to increased electricity demand. GSR-CC has a significantly higher levelized cost of electricity (LCOE) than its reference NGCC (natural gas combined cycle) plant, suggesting it is less competitive; however, increasing production scale could make it more attractive. Life-cycle results for GSR-H2 indicate NG consumption drives ∼ 75% of total global warming impacts (∼2.3 kg CO2 eq/kg H2). An environmental, health, and safety screening suggests iron-based carriers are comparatively safer, whereas NiO may pose greater risks. Overall, GSR-H2 is a scalable, competitive option for hydrogen production using nickel and non-nickel OC.
03 NATURAL GAS↗
Preliminary Techno-Economic Assessment of Gas Switching Reforming (GSR) of Natural Gas for Pure Hydrogen Production and Power Generation with Integrated CO2 Capture
The increasing demand for hydrogen and the CO2 intensity of natural gas (NG) reforming motivate the development of low-carbon-emission hydrogen production technologies. Gas Switching Reforming (GSR) is an advanced auto-thermal reforming technology that produces hydrogen or syngas from natural gas. It integrates inherent CO2 capture by utilizing a specialized oxygen carrier in a single fluidized bed reactor, eliminating the need for complex, energy-intensive post-combustion separation. GSR technology builds upon Chemical Looping Reforming (CLR), an experimentally proven technology with strong potential for scaling up. In this study, select oxygen carriers (OC) (NiO/Al2O3, Fe2O3-CeO2/Al2O3, and magnetite) were tested in methane steam reforming in a fixed bed reactor to determine their relative reactivities under relevant conditions for GSR (800 °C, 7 bar total pressure). Process models were then developed to perform techno-economic analysis (TEA) of GSR for hydrogen production (GSR-H₂) and a combined cycle (GSR-CC) in which high-purity H₂ is fired in a gas turbine to produce electricity. Operating at 10 bar and 1100 °C and with the additional recovery steps implemented increased H₂ production by ~30% and improved efficiency relative to prior studies. For GSR-H₂, the levelized cost of hydrogen (LCOH) is 1.61–1.64 $/kg-H₂, competitive with a reference SMR case, though operating and maintenance costs are higher due to increased electricity demand. GSR-CC has a significantly higher levelized cost of electricity (LCOE) than its reference NGCC (natural gas combined cycle) plant, suggesting it is less competitive; however, increasing production scale could make it more attractive. Life-cycle results for GSR-H2 indicate NG consumption drives ~75% of total global warming impacts (~2.3 kg CO2 eq/kg H2). An environmental, health, and safety screening suggests iron-based carriers are comparatively safer, whereas NiO may pose greater risks. Overall, GSR-H2 is a scalable, competitive option for hydrogen production using nickel and non-nickel OC.
03 NATURAL GAS↗
An advanced carbon reactor subsystem for carbon dioxide reduction
An evaluation is presented of the development status of an advanced carbon-reactor subsystem (ACRS) for the production of water and dense, solid carbon from CO2 and hydrogen, as required in physiochemical air revitalization systems for long-duration manned space missions. The ACRS consists of a Sabatier Methanation Reactor (SMR) that reduces CO2 with hydrogen to form methane and water, a gas-liquid separator to remove product water from the methane, and a Carbon Formation Reactor (CFR) to pyrolize methane to carbon and hydrogen; the carbon is recycled to the SMR, while the produce carbon is periodically removed from the CFR. A preprototype ACRS under development for the NASA Space Station is described.
Noyes, Gary P.↗
Analysis of synergies in converting underground storage sites: Natural gas to hydrogen with co-located CO2 storage
This study examines the untapped potential of synergistically converting underground natural gas storage (UGS) into underground hydrogen storage (UHS) with co-located CO2 storage. Current approaches to subsurface storage technology (SST) development often prioritise single-use scenarios, overlooking the benefits of integrating multiple technologies. We investigate converting UGS assets into UHS through gradual cushion-gas injection over multiple years, rather than injecting all cushion gas in the first year, and include on-site CO2 storage to offset site emissions. Mechanistic modelling shows this gradual transition reduces the Levelised Cost of Storage (LCOS) of H2 by 1.2-13.1% while retaining energy output within 3% of the current status quo. We also show that combined UHS and CO2 storage hubs can reduce the LCOS of CO2 by 45-77% for only a 3-10% increase in hydrogen LCOS relative to the status quo. This analysis framework may help future-proof SST sites and support a resilient, economically beneficial energy transition.
Mouli-Castillo, Julien↗
Low-pressure methanol synthesis from CO 2 over metal-promoted Ni-Ga intermetallic catalysts
Ni-Ga and M-Ni-Ga (M = Au, Co, Cu) catalysts were evaluated for methanol synthesis from CO 2 at 10 bar and 200-270°C. The following trend in turnover frequency (TOF) for CO 2 hydrogenation was observed: AuNiGa > CuNiGa > NiGa > CoNiGa, where TOF increased with decreasing catalyst affinity for CO. The presence of a third metal was found to influence both the formation of the Ni-Ga intermetallic phase as well as the number of available sites for CO chemisorption. Phase formation, catalyst composition and stability were evaluated using therm ogravimetric analysis (TGA), X-ray diffraction (XRD), X-ray fluorescence (XRF), scanning transmission electron microscopy and energy dispersive X-ray spectroscopy (STEM-EDX). Au-Ni-Ga, which showed a nearly 4-fold improvement in TOF at 263°C and 10 bar compared to Ni-Ga, consisted of Ni 3 Ga particles decorated with Au, as evidenced by post catalysis characterization.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Advanced Ceramic Membranes/Modules for Ultra Efficient Hydrogen (H2) Production/Carbon Dioxide (CO2) Capture for Coal-Based Polygeneration Plants: Fabrication, Testing, and CFD Modeling
Inorganic membrane-based systems are a promising technology for precombustion CO2 capture with simultaneous H2 production. State-of-the-art packages for high temperature and pressure service consist of multiple tube membrane bundles prepared in a "candle filter" configuration, in which the membrane tubes are open at one end and sealed at the other. This configuration is used for practical reasons, specifically the need to minimize problems due to thermal expansion mismatch between the ceramic tube bundle and the steel housing. However, the primary technical problem with the candle filter format for commercial-scale installations is the inability to purge the tube side (typically the permeate side), a feature that is crucial for high H2 recovery. In this study, the focus is to design and fabricate the first dual-end open full ceramic multiple tube membrane bundle that enables tube side (permeate) purge for gas separation applications. An additional key feature of this design is the simplified module layout, as the membrane bundles can be installed end-to-end with tube side (permeate) flow directly from one bundle to the next. This layout simplifies the membrane to housing seals and yields significant improvement in membrane packing density. Detailed focus areas in our studies include: (i) Materials development and preparation of the tube-to-tube sheet potting for the dual-ended bundle; (ii) the sealing and optimal module configuration design to minimize membrane stress upon module mounting; (iii) the demonstration, via the fabrication of CMS and Pd-alloy membranes supported on full-size, dual-ended ceramic support bundles, of the first example of a purgeable ceramic membrane and module; and (iv) development of a CFD model of the membrane module for calculation of feed flow distribution, and for use in scale-up, and capital cost estimating. The CFD model was validated using experimental data with the multi-tubular membrane system, employing He/N2 as a model gas mixture (surrogate for H2/CO2), and has been shown to be quite accurate. Employing the model, we are able to study the effects of operating pressure and temperature, feed and sweep gas flow rates, and the choice of membrane tube configuration on system performance.
20 FOSSIL-FUELED POWER PLANTS↗
Advanced Ceramic Membranes/Modules for Ultra Efficient Hydrogen (H2) Production/Carbon Dioxide (CO2) Capture for Coal-Based Polygeneration Plants: Fabrication, Testing and CFD Modeling
Inorganic membrane-based systems are a promising technology for precombustion CO2 capture with simultaneous H2 production. State-of-the-art packages for high temperature and pressure service consist of multiple tube membrane bundles prepared in a "candle filter" configuration, in which the membrane tubes are open at one end and sealed at the other. This configuration is used for practical reasons, specifically the need to minimize problems due to thermal expansion mismatch between the ceramic tube bundle and the steel housing. However, the primary technical problem with the candle filter format for commercial-scale installations is the inability to purge the tube side (typically the permeate side), a feature that is crucial for high H2 recovery. In this study, the focus is to design and fabricate the first dual-end open full ceramic multiple tube membrane bundle that enables tube side (permeate) purge for gas separation applications. An additional key feature of this design is the simplified module layout, as the membrane bundles can be installed end-to-end with tube side (permeate) flow directly from one bundle to the next. This layout simplifies the membrane to housing seals and yields significant improvement in membrane packing density. Detailed focus areas in our studies include: (i) Materials development and preparation of the tube-to-tube sheet potting for the dual-ended bundle; (ii) the sealing and optimal module configuration design to minimize membrane stress upon module mounting; (iii) the demonstration, via the fabrication of CMS and Pd-alloy membranes supported on full-size, dual-ended ceramic support bundles, of the first example of a purgeable ceramic membrane and module; and (iv) development of a CFD model of the membrane module for calculation of feed flow distribution, and for use in scale-up, and capital cost estimating. The CFD model was validated using experimental data with the multi-tubular membrane system, employing He/N2 as a model gas mixture (surrogate for H2/CO2), and has been shown to be quite accurate. Employing the model, we are able to study the effects of operating pressure and temperature, feed and sweep gas flow rates, and the choice of membrane tube configuration on system performance.
20 FOSSIL-FUELED POWER PLANTS↗
Mars Atmospheric In Situ Resource Utilization Projects at the Kennedy Space Center
The atmosphere of Mars, which is 96 percent carbon dioxide (CO2), is a rich resource for the human exploration of the red planet, primarily by the production of rocket propellants and oxygen for life support. Three recent projects led by NASAs Kennedy Space Center have been investigating the processing of CO2. The first project successfully demonstrated the Mars Atmospheric Processing Module (APM), which freezes CO2 with cryocoolers and combines sublimated CO2 with hydrogen to make methane and water. The second project absorbs CO2 with Ionic Liquids and electrolyzes it with water to make methane and oxygen, but with limited success so far. A third project plans to recover up to 100 of the oxygen in spacecraft respiratory CO2. A combination of the Reverse Water Gas Shift reaction and the Boudouard reaction eventually fill the reactor up with carbon, stopping the process. A system to continuously remove and collect carbon has been tested with encouraging results.
oxygen production and recovery↗
Mars Atmospheric In Situ Resource Utilization Projects at the Kennedy Space Center
The atmosphere of Mars, which is approximately 95% carbon dioxide (CO2), is a rich resource for the human exploration of the red planet, primarily by the production of rocket propellants and oxygen for life support. Three recent projects led by NASA's Kennedy Space Center have been investigating the processing of CO2. The first project successfully demonstrated the Mars Atmospheric Processing Module (APM), which freezes CO2 with cryocoolers and combines sublimated CO2 with hydrogen to make methane and water. The second project absorbs CO2 with Ionic Liquids and electrolyzes it with water to make methane and oxygen, but with limited success so far. A third project plans to recover up to 100% of the oxygen in spacecraft respiratory CO2. A combination of the Reverse Water Gas Shift reaction and the Boudouard reaction eventually fill the reactor up with carbon, stopping the process. A system to continuously remove and collect carbon is under construction.
in situ resource utilization↗
Recent advances in carbon dioxide hydrogenation to produce olefins and aromatics
Not Available
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Hydrogen Storage for Flexible Fossil Fuel Power Generation: Integration of Underground Hydrogen Storage with Gas Turbine (Final Report)
As the nation continues to encourage, through market structures and financial incentives, the proliferation of intermittent renewable electricity, how to optimize the ever-changing electric grid and identify means to retain and improve resilience, while ensuring continued reductions in GHG emissions, will be critical. According to Bloomberg, wind & solar generated 10.5% of US electricity in 2020 and that percentage continues to grow. In support of expanding renewable energy use, and to address its intermittent nature, this project will develop the Hydrogen Storage for Flexible Fossil Fuel Power Generation platform that is dispatchable, reliable, repeatable and have the ability to produce zero or negative carbon power while interfacing with geology capable of CO2 and hydrogen storage. GTI Energy (GTIE) and team members Illinois State Geological Survey (ISGS), Mitsubishi Heavy Industries America (MHIA), Ameren Illinois, Hexagon Purus, and the Low Carbon Resources Initiative (LCRI) completed a Phase I Conceptual Study under contract DE-FE0032012 for Hydrogen Storage for Flexible Fossil Fuel Power Generation: Integration of Underground Hydrogen Storage with Gas Turbine. The Hydrogen Storage for Flexible Fossil Fuel Power Generation platform addresses the intermittent nature of the expanding use of Variable Renewable Energy (VRE) generation. The low cost of the electricity (COE) generated results in greater dispatch and more operation at higher power levels (higher efficiency), fewer short intervals, and fewer start/stop cycles. The reliable, resilient system can produce zero carbon power and store hydrogen. It will demonstrate hydrogen storage in geologic formations like those used in natural gas underground storage thus enabling large scale storage of hydrogen in sedimentary strata across the United States rather than in geographically restricted salt caverns. The Phase I study confirmed the system is feasible and generates power at lower cost than other low carbon approaches. The demonstration defines the pathway for broad commercial application and will accelerate the development of larger systems suitable for centralized utility scale electricity production. The study advanced the maturity of the H 2 storage-based system with flexible power generation by completing a Pre-FEED study (Phase II). The Pre-FEED focused on the selected Energy Farm on the University of Illinois Urbana-Champaign (UIUC) site that includes above ground and underground hydrogen storage, low-carbon hydrogen production (GTI’s Compact Hydrogen Generator, CHG) with underground CO2 sequestration, and a 40-MW class gas turbine. The Pre-FEED addressed the entire system and its interconnection to the natural gas and electric grid and mitigation of key risks, such as storage behavior, load-following, and system operation. During Phase 1 of the project, the team completed key tasks, which moved the entire demonstration project, specific components and approaches closer to commercialization. These Phase I Accomplishments include: Completing System Requirements Review; Completing System Layout and Modeling - Heat & Mass Balance and Process Flow Diagram; Completing modelling of 9 turbine performance cases; Evaluating rock strata for underground storage of hydrogen and sequestration of carbon dioxide; Completing initial modelling of underground storage of hydrogen and withdrawal with evaluation of loss and water production; Identifying roadable storage for above ground hydrogen storage; Identifying existing electrical infrastructure for receiving/delivering electricity; Identifying existing gas supply infrastructure for receiving natural gas; Document concept design/development plans in required reports. Conclusions: The 12-month Feasibility study in Phase I study was completed and confirmed the system is feasible and generates power at lower cost than other low carbon approaches and even lower cost than the reference NGCC plant without carbon capture when taking advantage of 45Q carbon credits. The study enabled the fidelity of the concept to be improved and allowed identification of the requirements for the system. Defining the individual system and component requirements was performed via the system requirements review with the whole team. These requirements were then incorporated into and iterated with our Heat & Mass Balance process model and process flow diagrams were generated to reflect the overall system. This information was then used to complete the TEA and show economic feasibility. Large scale non-salt geologic storage of hydrogen is an enabling technology for a hydrogen-fired turbine that can be retrofitted into large-scale electric generating units (EGU). Our demonstration will include 428 MWh or ~4 hours full load of hydrogen storage (above and underground). Carbon capture inherent to the CHG process can capture 90% CO 2 (with upgrades to >98%). This system provides a COE of 23% savings relative to an NGCC with a post combustion amine system. Our proposed storage system decouples carbon capture and hydrogen production from power production; therefore, we expect our proposed system’s efficiency and variable COE to be superior resulting in overall higher dispatch and reduced deep cycling. Our demonstration will be full to multi-day hydrogen storage and has the potential for longer (seasonal) duration commercially. The demonstration defines the pathway for broad commercial application and will accelerate the development of larger systems suitable for centralized utility scale electricity production.
03 NATURAL GAS↗
Assessing the Relative Climate Impact of Carbon Utilization for Concrete, Chemical, and Mineral Production
Estimates show that 6.2 gigatons of carbon dioxide (CO2) can be captured and utilized across three pathways, concrete, chemical, and minerals, by 2050. However, it is difficult to compare the climate benefit across these three carbon capture and utilization (CCU) pathways to determine the most effective use of captured CO2. The life cycle assessment methods to evaluate the climate benefit of CCU chemicals should additionally account for the change in material properties of concrete due to CO2 utilization. Furthermore, with most CO2 utilization technologies being in the early stages of research and development, the uncertainty and variability in process and inventory data present a significant challenge in evaluating the climate benefit. We present a stochastically determined climate return on investment (ROI) metric to rank and prioritize CO2 utilization across 20 concrete, chemical and mineral pathways based on the realized climate benefit. We show that two concrete pathways, which use CO2 during concrete mixing, and two chemical pathways, which produce formic acid through hydrogenation of CO2 and carbon monoxide through dry reforming of methane, generate the greatest climate ROI and are the only CCU pathways with a higher likelihood of generating a climate benefit than a climate burden.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Comparative assessment of new oxygen carrier materials for gas switching reforming of natural gas: Techno-economics assessment, life cycle analysis, and experimental insights
The increasing demand for hydrogen and the CO 2 intensity of natural gas (NG) reforming motivate the development of low-carbon-emission hydrogen production technologies. Gas Switching Reforming (GSR) with integrated CO 2 capture, a technology based on Chemical Looping Reforming (CLR), has been experimentally proven and shows potential for scale-up. In this study, select oxygen carriers (OC) (NiO/Al 2 O 3 , Fe 2 O 3 -CeO 2 /Al 2 O 3 , and magnetite) were tested in methane steam reforming in a fixed bed reactor to determine their relative reactivities under relevant conditions for GSR (800 °C, 7 bar total pressure). Process models were then developed to perform techno-economic analysis (TEA) of GSR for hydrogen production (GSR-H 2 ) and a combined cycle (GSR-CC) in which high-purity H 2 is fired in a gas turbine to produce electricity. Operating at 10 bar and 1100 °C and with the additional recovery steps implemented increased H 2 production by ∼ 30% and improved efficiency relative to prior studies. For GSR-H 2 , the levelized cost of hydrogen (LCOH) is 1.61–1.64 $/kg-H 2 , competitive with a reference SMR case, though operating and maintenance costs are higher due to increased electricity demand. GSR-CC has a significantly higher levelized cost of electricity (LCOE) than its reference NGCC (natural gas combined cycle) plant, suggesting it is less competitive; however, increasing production scale could make it more attractive. Life-cycle results for GSR-H 2 indicate NG consumption drives ∼ 75% of total global warming impacts (∼2.3 kg CO 2 eq/kg H 2 ). An environmental, health, and safety screening suggests iron-based carriers are comparatively safer, whereas NiO may pose greater risks. Overall, GSR-H 2 is a scalable, competitive option for hydrogen production using nickel and non-nickel OC.
03 NATURAL GAS↗
Performance and cost analysis of liquid fuel production from H 2 and CO 2 based on the Fischer-Tropsch process
Electro-fuels can be produced from concentrated sources of carbon dioxide and hydrogen using electricity generated from renewable sources; this process enables energy storage at high volumetric energy density. Among the electro-fuels options, FT (Fischer-Tropsch) fuel is attractive for heavy-duty trucks and non-road transportation applications. This study conducts a techno-economic analysis of FT liquid fuel production from H 2 and CO 2 using a detailed performance analysis. Minimum fuel selling price is estimated for a broad range of H 2 and CO 2 prices and for a range of potential CO 2 credits. The analysis indicates that H 2 price has the largest impact on the minimum selling price of FT fuel. FT fuel production with a CO 2 price of $17.3/metric ton requires an H 2 price of $0.8/kg to be cost-competitive with the pre-tax petroleum diesel price of $3.1/gal in 2050 (before the application of any CO 2 credits). When the H 2 price is $2.0/kg from central water electrolysis (2020 target), the minimum selling price of the FT fuel is $5.4–5.9/gal. A sensitivity analysis shows that future system optimization of FT fuel production could focus on improving the H 2 and CO 2 recycle contributions and FT fuel conversion ratio. The analysis results can be combined with various upstream systems for H 2 and CO 2 production.
08 HYDROGEN↗