Periodic Reporting for period 1 - South Beach (CO2-free, on-demand, on-site production of low-cost green hydrogen produced with micro-wave plasma)
Reporting period: 2022-10-01 to 2023-08-31
Decarbonated gas is the key ingredient of the energy transition, particularly for the decarbonization of the industry. In this context, hydrogen is being promoted as a CO2-free alternative to burning fossil fuels, whose use as an energy source must be severely restricted to minimise the impact on climate change. Hydrogen gas is produced by three main processes:
1. The traditional hydrogen production process is methane steam reforming, which produces large amounts of CO2: even if associated with CCS technologies.
2. Water electrolysis consumes large amounts of energy and requires large footprints to make the process cost effective;
3. The direct decomposition of methane into hydrogen gas and solid carbon can require significantly less energy than water electrolysis and does not emit CO2. This process, known as methane pyrolysis, is usually used to produce valuable carboneous material at high temperatures. But, with adaptations it can address the energy transition.
Sakowin's main objective is to contribute to the energy transition with a sustainable solution to produce a clean hydrogen for use as a fuel in industrial processes and to co-produce CO2-free solid carbon (carbon black). To this end, Sakowin is developing a highly energy efficient methane plasmalysis (methane pyrolysis using a plasma source) equipment based on microwave excited plasma at atmospheric pressure to produce hydrogen and solid carbon using natural gas (NG) or biomethane as feedstock, hence removing the GHG emission.
Sakowin's equipment is compact, modular and stackable. It can be integrated into existing industrial and gas infrastructures for on-site and on-demand production, with capacity that can be easily adapted to a wide range of industries and facilities.
1. The traditional hydrogen production process is methane steam reforming, which produces large amounts of CO2: even if associated with CCS technologies.
2. Water electrolysis consumes large amounts of energy and requires large footprints to make the process cost effective;
3. The direct decomposition of methane into hydrogen gas and solid carbon can require significantly less energy than water electrolysis and does not emit CO2. This process, known as methane pyrolysis, is usually used to produce valuable carboneous material at high temperatures. But, with adaptations it can address the energy transition.
Sakowin's main objective is to contribute to the energy transition with a sustainable solution to produce a clean hydrogen for use as a fuel in industrial processes and to co-produce CO2-free solid carbon (carbon black). To this end, Sakowin is developing a highly energy efficient methane plasmalysis (methane pyrolysis using a plasma source) equipment based on microwave excited plasma at atmospheric pressure to produce hydrogen and solid carbon using natural gas (NG) or biomethane as feedstock, hence removing the GHG emission.
Sakowin's equipment is compact, modular and stackable. It can be integrated into existing industrial and gas infrastructures for on-site and on-demand production, with capacity that can be easily adapted to a wide range of industries and facilities.
The achievements are based on 4 main pillars:
1. Modelling and practical model validation
Aim: 2.45 GHz microwave (electromagnetic) plasma model for the methane decomposition reaction.
A plasma containing a mixture of gases including methane (CH4) was studied. In this study, the electromagnetic model has been coupled to a plasma model which describes in detail the plasma kinetics and the chemistry likely to occur in a plasma environment. The model developed will allow both the understanding of the chemical kinetics of CH4 decomposition using microwave generated plasma and the development of a realistic 3D model describing the experimental setup in detail, which can be subsequently extended to include more chemical reactions and to study other plasma sources.
The theoretical model will be compared with experimental measurements from the benchmark test facility built for this purpose at Sakowin and with results published in scientific papers.
2. Laboratory unit 6 kW, 2.45 GHz
Aim: Experimental research on microwave plasma methane decomposition, gas-solid separation and gas-gas separation. Development of analytical methods for the gas and solid phases.
The plasmalysis of methane emitted from a cylinder or from natural gas was studied and characterised with respect to parameters related to microwave and plasma generation (power, plasma ignition) and to the chemical reaction - gas and solid phase composition vs. inlet gas type and concentration, pressure and temperature. The results of this work made it possible to establish analytical methods for the gas and solid phases, which helped in the dimensioning of the plasma reactor, the gas-solid separation, the gas-gas separation. The control software and hardware for the equipment was designed and built in-house. A Hazard and Operability (HAZOP) study was conducted to identify design and engineering issues with respect to the design of the SouthBeach 6000 research unit, as described below.
3. Design, development and construction of the SouthBeach 6000, an industrial research unit for the production of hydrogen and solid carbon.
Aim: To build an industrial research unit to study the methane microwave plasmalysis process for the production of hydrogen and solid carbon and to investigate the compatibility of both products with various industrial applications.
The first complete South Beach 6000 unit has been fully completed and installed at Sakowin's premises. The unit consists of four (4) interconnected metal cabinets, namely Electrical and Control, Process/Plasmalysis Reactor, Gas-Solid Separation, Gas-Gas Separation & Hydrocarbon Recirculation. The unit operates with natural gas as the main inlet gas as well as other gas molecules/compositions to replicate industrial conditions.
4. Design and construction of the 915 MHz testbed
Aim: To develop the test and construction site for Sakowin's 100kW industrial pilot, which will be commercialised for beta testing.
The test site was designed and built to industrial standards including all utilities, i.e. cooling water, natural gas, compressed air, nitrogen, electrical power, ATEX exhaust extraction, required for parallel operation of the 100 kW industrial pilot, the SouthBeach 6000 and any other additional equipment that may be required to further meet customer requirements, e.g. cogeneration of electricity, various hydrocarbons such as LPG used as feed gas.
1. Modelling and practical model validation
Aim: 2.45 GHz microwave (electromagnetic) plasma model for the methane decomposition reaction.
A plasma containing a mixture of gases including methane (CH4) was studied. In this study, the electromagnetic model has been coupled to a plasma model which describes in detail the plasma kinetics and the chemistry likely to occur in a plasma environment. The model developed will allow both the understanding of the chemical kinetics of CH4 decomposition using microwave generated plasma and the development of a realistic 3D model describing the experimental setup in detail, which can be subsequently extended to include more chemical reactions and to study other plasma sources.
The theoretical model will be compared with experimental measurements from the benchmark test facility built for this purpose at Sakowin and with results published in scientific papers.
2. Laboratory unit 6 kW, 2.45 GHz
Aim: Experimental research on microwave plasma methane decomposition, gas-solid separation and gas-gas separation. Development of analytical methods for the gas and solid phases.
The plasmalysis of methane emitted from a cylinder or from natural gas was studied and characterised with respect to parameters related to microwave and plasma generation (power, plasma ignition) and to the chemical reaction - gas and solid phase composition vs. inlet gas type and concentration, pressure and temperature. The results of this work made it possible to establish analytical methods for the gas and solid phases, which helped in the dimensioning of the plasma reactor, the gas-solid separation, the gas-gas separation. The control software and hardware for the equipment was designed and built in-house. A Hazard and Operability (HAZOP) study was conducted to identify design and engineering issues with respect to the design of the SouthBeach 6000 research unit, as described below.
3. Design, development and construction of the SouthBeach 6000, an industrial research unit for the production of hydrogen and solid carbon.
Aim: To build an industrial research unit to study the methane microwave plasmalysis process for the production of hydrogen and solid carbon and to investigate the compatibility of both products with various industrial applications.
The first complete South Beach 6000 unit has been fully completed and installed at Sakowin's premises. The unit consists of four (4) interconnected metal cabinets, namely Electrical and Control, Process/Plasmalysis Reactor, Gas-Solid Separation, Gas-Gas Separation & Hydrocarbon Recirculation. The unit operates with natural gas as the main inlet gas as well as other gas molecules/compositions to replicate industrial conditions.
4. Design and construction of the 915 MHz testbed
Aim: To develop the test and construction site for Sakowin's 100kW industrial pilot, which will be commercialised for beta testing.
The test site was designed and built to industrial standards including all utilities, i.e. cooling water, natural gas, compressed air, nitrogen, electrical power, ATEX exhaust extraction, required for parallel operation of the 100 kW industrial pilot, the SouthBeach 6000 and any other additional equipment that may be required to further meet customer requirements, e.g. cogeneration of electricity, various hydrocarbons such as LPG used as feed gas.
One of the main commercial achievements was the construction and sale of a laboratory unit, SouthBeach 3000, ordered and used by the Swiss laboratory EMPA for own research on the co-produced carbon; this unit was successfully commissioned and started up in October 2022. A second achievement was the collaboration agreement signed in 2023 with the Swiss Association for the Decarbonization of Industry (VzDI) for which Sakowin has been appointed to manufacture a 100kW industrial pilot that will be installed in Zug, near Zürich.
Industry sectors are commonly qualified as hard to abate and demonstrate a strong interest in Sakowin’s solution. Sakowin is planning the release and install 10 to 15 industrial pilot units prior to the release of the standardized product in 2026.
Industry sectors are commonly qualified as hard to abate and demonstrate a strong interest in Sakowin’s solution. Sakowin is planning the release and install 10 to 15 industrial pilot units prior to the release of the standardized product in 2026.