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FY2005 FRED Database Project Description:

Project Information

 

 

Project Title:

Catalytic Methane Decomposition for CO2 Free Hydrogen Production

 

Project I.D.:

FWP 4661-08

 

FE Program:

Gas/Oil - Oil Production R&D

 

Research Type:

To Be Provided          

 

Funding Memorandum:

Field Office Work Agreement            

 

 

Project Performer

 

 

Performer Type:

DOE/National Laboratory

 

Performer:

Idaho National Engineering and Environmental Laboratory (INEEL)

 

Performer Address:

P.O. Box 1625
850 Energy Drive
Bechtel BWXT Idaho, LLC

 

Other Project Team Members:

 

 

 

Project Dates

 

 

Project Start Date:

15-Aug-04

 

Project End Date:

9-Aug-05

 

 

Project Location

 

 

City:

Idaho Falls

 

State:

ID

 

ZIP Code:

83415-1563

 

Congressional District:

2

 

Responsible FE Site:

NETL

 

 

Project Contact

 

 

Name:

Ginosar, Daniel M.

 

Telephone:

(208) 526-9049

 

Fax Number:

(208) 526-8541

 

Email Address:

DMG@INEL.GOV

 

 

DOE/FE Contact

 

 

Name:

Stirling, Kathleen Q.

 

Telephone Number:

(918) 699-2008

 

Site Location:

NETL

 

Email Address:

kathy.stirling@netl.doe.gov

 

 

Cost & Funding Info.

 

 

Total Estimated Cost:

$125,000

 

DOE Share:

$125,000

 

Non-DOE Share:

$0

 

 

Project Description

 

 

Project Description:

Examine methane decomposition for the production of hydrogen and solid carbon; and will accomplish the following tasks:  Experimental sytem modifications and approvals to allow for overnight catalyst testing; Catalyst optimization for the purpose of increasing hydrogen yields; Extended catalyst testing for up to one full week of continous hydrogen production using promising catalysts developed in this study; Energy and mass balances calculations using a process simulation code such as ASPEN Plus to estimate energy conversion efficiencies and compare those to steam reforming; Technology protection; communication and transfer for the purpose of transferring the technology to industry.

 

Project Background:

Through the project Proton Exchange Reactive Membranes for Conversion of Light Alkanes to Clean Liquid Fuels funded by DOE-FE's Downstream Environmental program; the Idaho National Engineering and Environmental Laboratory (INEEL) has developed a stable and efficient catalyst for converting methane to hydrogen without the generation of carbon dioxide.  This catalytic process could provide a significant advance in the development of the hydrogen economy utilizing natural gas without the production of greenhouse gasses.

This catalyst resulted in continuous production of hydrogen from methane at high conversions and high hydrogen yields.  The catalyst was found to have stable activity in tests as long as 30 hours in duration in a continuous flow; packed bed experimental test stand.  Tests were performed at atmospheric pressure; at temperatures from 500 to 700  C; and at industrially relevant weight hourly space velocities up to 2.5 g CH4 per g catalyst per hour.  In the absence of catalyst; the reaction did not take place.

The reaction explored is the direct catalytic decomposition of methane to hydrogen gas and solid carbon.  Solid carbon particles produced flow out of the catalyst bed and could be collected in downstream equipment.  Although we have not analyzed the solid product; carbon produced from natural gas is expected to be of high quality since it would contain very low levels of sulfur and metals.  Thus it could be utilized in high-value materials enhancing applications.  If carbon production exceeded demand; it could be disposed of at significantly lower costs compared to carbon dioxide sequestration; and with higher assurances of long term stability.  Additionally; since no other gases are produced in the process the hydrogen is free of CO contamination; and gas separation is simple.

Catalysts for this process would be within standard industrial costs.  The catalyst was produced using a mix of proprietary metal salts that were deposited within a common high-surface area; microporous support.  Without optimization of the catalyst; reactor or process conditions; methane conversions over 50 % were obtained with corresponding high hydrogen yields.  Higher conversions are anticipated with system optimizations; however; any unreacted methane would of course be recycled leading to 100% conversion of methane to hydrogen and elemental carbon. Reactor and associated unit operation capital costs are also anticipated to be low; since the reactor and separations are simple and do not require development of new technologies.

Additional research is needed for the technology to reach fruition.  Efforts are needed in the areas of catalyst optimization; process optimization; reactor development and carbon analysis.  In addition; market analysis for the high-quality carbon product and processes economic analysis will need to be performed.

The most promising near-term solution for generating hydrogen is to use the feedstock that refineries have been employing for decades; natural gas.  To realize a greenhouse gas free hydrogen economy; carbon dioxide must be sequestered or not produced.  This catalytic route offers a promising path for economical; environmentally sound production of hydrogen.

 

Project Accomplishments:

[NOTE: Updated information not available beginning 2004]

30-Aug-04:
Accomplishment: New Project Initiated
Description: New funding for this project was received in August.  This project will explore the catalyst discovered in the Proton Exchange Reactive Membranes project for the production of hydrogen and solid carbon by the decomposition of methane.  The CRADA with Ceramatec Inc. is being modified to cover this new work scope.

 

 

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