Scaleable, High Efficiency Microchannel Sabatier Reactor
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45th International Conference on Environmental Systems ICES-2015-240 12-16 July 2015, Bellevue, Washington Scaleable, High Efficiency Microchannel Sabatier Reactor John O. Thompson1 UMPQUA Research Company, Myrtle Creek ,OR, 97457 An innovative Microchannel Sabatier Reactor System has been developed for the efficient production of oxygen (as water) and methane from carbon dioxide (CO2), a valuable in situ resource available in the atmosphere or as frozen deposits on Mars and other Near Earth Objects, which will help mitigate mission resupply logistics and risk. The Sabatier reaction benefits from inherently superior micro reactor heat and mass transfer characteristics compared to conventional reactor designs. Significantly, graded temperature micro reactors can readily be configured in a parallel arrangement to vastly improve conversion efficiencies. Process scale-up is easily achieved by increasing the number of equivalent, parallel micro reactors. High conversion rates require the deposition of a highly active, supported catalyst layer onto microchannel walls that is characterized by enhanced surface area, appropriate adsorption characteristics, and catalyst effectiveness factor. A core focus of the research effort was the design of a MSRS that optimizes residence time, thermal recovery, and most importantly, the achievement of near equilibrium reaction product composition at low temperature. A three stage reactor consisting of a supported noble metal catalyst on stainless steel tubing and sequentially heated to 365, 294, and 234 degrees centigrade demonstrated 96% single pass conversion efficiencies of CO2 to methane for an influent gas composition of 4:1 H2:CO2. Nomenclature MSRS = microchannel Sabatier reactor system ISRU = in situ resource utilization ESM = equivalent system mass CRA = carbon dioxide reduction assembly ESA = European Space Agency JAXA = Japanese Aerospace Exploration Agency RWGS = reverse water-gas shift PNNL = Pacific Northwest National Laboratory EISA = Evaporation Induced Self Assembly I. Introduction Oxygen is an important oxidant for high specific energy, chemical fuels such as hydrogen and methane, and oxygen and water are arguably two of the most critical resources for life-support. As such, means to extract O2 and H2O from in situ CO2 are needed to support future Mars exploration missions. Various techniques have been proposed and evaluated for oxygen extraction from the predominantly CO2 Martian atmosphere for ISRU. These include the reduction of Martian carbon dioxide using either the Sabatier or Bosch reactions. The Sabatier reaction is given by Equation 1, in which, methane and water vapor are formed, typically in a fixed- bed catalytic reactor. Using a variety of catalysts and reactor configurations, this reaction has been studied 1- extensively for the recovery of O2 (as water via electrolysis) from CO2 for employment aboard manned spacecraft. 10 The chief limitation to this approach for ISRU applications is the requirement to supply hydrogen lost in the methane byproduct, although methane may be used as an in situ generated propellant. 1 Principal Investigator, R&D, Address: UMPQUA Research Company PO Box 609 Myrtle Creek OR 97457. Ru/Al23 O CO22 + 4H → 2H2 O + CH 4 (1) The Bosch reaction,11-15 given by Equation 2, is another well-known process allowing the recovery of oxygen from carbon dioxide by reacting it with hydrogen at elevated temperature in the presence of appropriate catalysts forming water vapor and elemental carbon (C). Fe / Co / Ni CO22 + 2H → 2H2 O + C(s) (2) The production of carbon by the Bosch reaction limits its usefulness due to degradation of reactor performance through catalyst degradation or reactor plugging. This situation results in a clear advantage to the entirely gas phase Sabatier reaction. The Sabatier reaction enables the complete recovery of O2 from CO2 via electrolysis of the H2O product. Hydrogen represents the only consumable in that only ½ of the consumed H2 is recovered by H2O electrolysis. The H2 reduction of CO2 via the Sabatier reaction results in the formation of H2O and CH4 (Equation 1). Both products of this exothermic reaction are valuable to space exploration. Methane can be used either as a propellant or as a H2 source, and the recovered H2O may be consumed pure, used to reconstitute dehydrated food, or electrolyzed to recover O2 and H2. Many heterogeneous catalysts have been thoroughly investigated for the Sabatier reaction, including a wide variety of catalytic metals and support materials. Industrial applications favor nickel (Ni), cobalt (Co), iron (Fe), and molybdenum (Mo) catalysts due to their reduced cost although these metals generally require higher temperatures to achieve reasonable kinetics.16-22 At lower temperatures involving special applications, for which expense is less important than activity, ruthenium (Ru) is primarily utilized either by itself or in combination with secondary metals such as palladium (Pd), rhodium (Rh), or platinum (Pt).23-31 To enhance catalyst performance, various materials have been utilized as catalyst supports, with titania (TiO2), alumina (Al2O3), and zirconia (ZrO2) supported catalysts being the most active.23,24,26,28,29,31 Heat removal is particularly important for the exothermic Sabatier reaction because the equilibrium conversion of CO2 drops below 100% above 100°C, and at temperatures between 400 and 500°C the equilibrium conversion drops from ~85% to 65%. This is shown in Figure 1, which illustrates the equilibrium products for the Sabatier reaction with a starting 4:1 molar ratio of H2:CO2. Maintaining precise thermal control of an exothermic reaction in a packed bed or conventional monolithic reactor is difficult due to intrinsic heat transfer limitations. These large- scale reactors can also have reduced effectiveness factors due to mass transfer limitations imposed by pore diffusion resistance and the relatively large bulk diffusion distances. Utilization of a graded temperature micro reactor will circumvent the shortcomings common in packed bed reactor systems. Micro reactors benefit from inherently high heat and mass transfer coefficients due to the exceptionally short heat and mass transfer distances.32,33 Advantages inherent in micro reactor systems have led to a dramatic increase in the investigation of their application to a wide variety of chemical processes ranging from fuel cells to hydrogen peroxide synthesis. Many of the chemistries related to hydrocarbon processing including desulfurization, petroleum cracking, biodiesel esterification and transesterification reactions, Fischer-Tropsch reactions, and syngas production, have been incorporated into micro reactors of various designs.34-37 0.5 0.4 0.3 0.2 H2 Species Quantity (kmoles)Species Quantity H2O 0.1 CH4 CO2 CO 0.0 0.0 100.0 200.0 300.0 400.0 500.0 600.0 Temperature (oC) Figure 1 Equilibrium Product Distribution Versus Temperature at a 4:1 H2:CO2 Ratio. 2 International Conference on Environmental Systems As previously mentioned, the Sabatier reaction is particularly well suited to a micro reactor because of the importance of temperature control. The thermodynamic data show that the equilibrium conversion declines from 100% at temperatures above ~100°C. The heat of reaction released during CO2 reduction will result in a significantly lower CO2 conversion if thermal control is not maintained and temperature increases. As the temperature rises, equilibrium increasingly favors secondary products such as CO. Unfortunately, the reaction kinetics are too slow to make operation at 100°C practical, and in fact, conversion rates do not approach equilibrium until approximately 400°C, depending on reactor activity and space velocities.23,24,26,29 This implies that conversion cannot exceed 85% in a single pass reactor operated above 400°C. The equilibrium may be shifted toward 100% by 38 increasing the H2 to CO2 ratio, but doing so reduces the savings to ESM because more H2 passes downstream and must be recovered or lost. In fact, the design for the Hamilton-Sundstrand developed CRA Sabatier reactor specifies 31,39 a 3.5:1 molar ratio of H2:CO2 to ensure maximum utilization of H2. This trade off between kinetics and equilibrium highlights the flexibility advantage of micro reactor systems, as a graded temperature micro reactor can operate with temperature profiles that maximize product yield and selectivity. In addition, a micro reactor array can be configured to provide the required process capacity by numbering up the system to meet process requirements. For example, a micro reactor with a channel cross-section of 250 µm by 1000 µm that consists of four U-shaped channels per layer and has ~30 layers has an internal volume of ~1.25 cm3. If this reactor were to see 2.0 L/min of CO2 mixed with H2 at a 1:4 molar ratio, the resultant residence time would be ~10 ms, which is insufficient for acceptable conversions at 400°C. A micro reactor array consisting of 40 parallel units would increase the residence time to 400 ms and enable the reaction to achieve equilibrium according to published micro reactor work.24,26,29 However, as previously indicated, the yield under these conditions is only 85%. A graded temperature micro reactor provides an alternative approach to overcoming these conversion limits by taking advantage of favorable high temperature kinetics in the first portion of the reactor and more favorable equilibria in the cooler length of the reactor. For example, if the CO2 flow rate is 1 mol/min at the reactor inlet, and reaction kinetics at 400°C are such that equilibrium is reached, then the outlet CO2 flow rate will be 0.15 mol/min. However, as the reactor temperature is reduced to 300°C, the equilibrium conversion improves to ~93%; resulting in an outlet CO2 flow of 0.07mol/min provided the contact time is sufficiently long. As the gas continues through the graded temperature micro reactor an exit temperature of 200°C could be achieved with nearly 100% conversion at equilibrium. Although reduction reaction kinetics diminish as temperature is reduced, significantly less reactant remains that must be consumed in the remaining contact time.