STructured unconventional reactors for CO2-fRee Methane catalytic crackING

Informations projet

STORMING

N° de convention de subvention: 101069690

DOI

10.3030/101069690

Projet clôturé

Date de signature de la CE 3 Juin 2022

Date de début 1 Septembre 2022

Date de fin 31 Août 2025

Financé au titre de

• Climate, Energy and Mobility

Coût total

€ 3 125 714,75

Contribution de l’UE

€ 3 125 714,75

Coordonné par

ALMA MATER STUDIORUM - UNIVERSITA DI BOLOGNA
Italy

Periodic Reporting for period 2 - STORMING (STructured unconventional reactors for CO2-fRee Methane catalytic crackING)

Période du rapport: 2024-03-01 au 2025-08-31

Résumé du contexte et des objectifs généraux du projet

H2 will contribute to the decarbonization of hard-to-abate sectors such as the chemical industry, glass, tiles, and steel manufacturing as well as freight transport. The production of economic H2 by a low CO2 emissions (the notorious greenhouse gas) process is a requisite.
STORMING is developing a catalytic process showing zero CO2 emissions. The biomethane from biogas is converted through a process powered by renewable electricity into pure H2 and highly valuable carbon nanotubes (CNTs) for battery applications.
Low cost, easily available and non-toxic iron-based innovative catalysts, and the electrification (joule, microwave, and induction heating) of 3D printed structured reactors are investigated to enable an accurate thermal control resulting in high energy efficiency.

Travail effectué depuis le début du projet jusqu’à la fin de la période considérée dans le rapport et principaux résultats atteints jusqu’à présent

The work has been focused on the smart rational catalyst design proposed in STORMING. This methodology combines modelling (computational simulations by high throughput density functional, DFT, and model catalysts) with experimental results from laboratory catalytic reactors and in situ/operando synchrotron characterization. A combination of Fe-based promoted catalysts and reaction conditions have been identified to simultaneously produce H2 and base grow CNTs. The key species and mechanisms involved in the CH4 activation and CNTs growth have been identified.
The environmentally friendly and economical process development is supported by Life Cycle Assessment (LCA) of the laboratory process and market analysis of H2 and CNTs production and a preliminary techno economical analysis.
The development of the electrified catalytic reactors has been performed with the production of the 3D printed monoliths and the setup of Joule, MW, and Induction heated reactors. The kinetic and micro-kinetic modelling of the CNTs growth and Computational Fluid Dynamics (CFD) simulations helped in the reactor design. Moreover, the purification technologies of the biogas and the H2 produced have been selected. The final Joule Heated TRL5 prototype was designed, assembled and validated.

Progrès au-delà de l’état des connaissances et impact potentiel prévu (y compris l’impact socio-économique et les conséquences sociétales plus larges du projet jusqu’à présent)

We have proposed, for the first time, base growth of CNTs on Fe-based catalysts under reaction conditions able to achieve H2 productivities above 5 LH2/gcat*h. The CNTs base growth has been demonstrated by ex situ and in situ characterization of real and model catalysts with techniques developed for this purpose. Meanwhile, the key role of the active phase on balancing the CH4 activation and C diffusion has been proved by computational and experimental studies, as well as the kinetic model. For the Induction heated reactor Fe–Ni–Co catalysts achieve the highest and most stable CH₄ conversion (> 40 %) and carbon yields (≈ 0.2 g h⁻¹) at 650 °C for more than 10 h, since they act as both magnetic susceptors and active catalytic phases.
The structuration of the catalyst by 3D printing confirmed the ability of the structured materials to decrease the reactor clogging and promote the Joule and MW heating.
These results are the basis for the further development of a continuous process in STORMING that will confirm the feasibility of the biomethane decomposition for the CO2-free production of H2, valorising the carbon as CNTs. Moreover, they will contribute to promote the research on cheap, easily available and non-toxic Fe-based catalysts. Last but not least, they provide a robust methodology for the development of other types of catalysts.