Bioeconomy Institute

Development of a Catalyst/Sorbent for Methane Reforming

The overall objective of this project is the development of a unique material that can improve the overall efficiency of producing hydrogen from coal. Therefore, the project can make an important contribution to the development of Vision 21 technologies for producing electrical power from coal more efficiently by using fuel cells supplied with hydrogen fuel. One of the most efficient methods for producing hydrogen from coal makes use of hydrogasification to produce methane, which is then reacted with steam at high temperature to produce hydrogen and carbon dioxide. For maximum efficiency, this reaction needs to be conducted in the presence of both a catalyst for the reaction and a sorbent for the carbon dioxide.

The sorbent serves both to drive the reaction and to separate the hydrogen and carbon dioxide. Phase I of this investigation has shown that a steam reforming catalyst and a carbon dioxide sorbent can be combined into a single pellet consisting of a calcium-based core encased in a porous shell impregnated with a nickel catalyst. This unique material is prepared by a simple two-stage pelletization process followed by calcination and then impregnation with a solution of nickel nitrate, which is subsequently decomposed by further heating. Since the shell is made largely of sintered alumina particles, it provides a strong protective shell as well as a good catalyst support.

Preliminary tests of the combined catalyst and sorbent have been conducted by employing thermal gravimetric analysis and also by employing a tubular reactor packed with the material. These tests have shown that the material improves the conversion of methane into hydrogen as well as providing a separation of the hydrogen and carbon dioxide. Therefore, it has met expectations and demonstrated a basic concept. During Phase II of the investigation, the combined catalyst and sorbent material is to be perfected in order to produce a highly serviceable material that is robust, sulfur tolerant, and long lived. To achieve these goals, improvements are to be made in the sorbent material, shell material, and catalyst. This requires preparing and testing numerous formulations of these components guided by an understanding of the technical literature and the basic principles of materials science.

Principal Investigators:

Brent Shanks, Iowa State University

Tom Wheelock, Iowa State University

Associated Contracts or Grants:

Development of a Catalyst/Sorbent for Methane Reforming, Department of Energy Award No. DE-FG26-04NT42182 (10/1/04-9/30/07)

Participating and/or Sponsoring Organizations:

United States Department of Energy