Syngas production and hydrogen separation technologies are very mature, and also extremely important for energy and chemical industries. Furthermore, these processes are the most expensive elements for many applications such as hydrogen production from renewable sources. Enhancing or intensifying these very mature technologies is very challenging, but would have tremendous impact on the performance and economics of many processes. Traditional Integrated Gasification Combined Cycle (IGCC) for syngas production need to include a carbon capture process in order to regulate their carbon dioxide emission as more and more countries and regions have implemented carbon tax policy. Integration of this process with Pd membrane has long been considered a key component to make it more feasible. With these two technologies combined together, we can produce high purity hydrogen while capturing carbon dioxide and toxic gases from the syngas product. Besides, although manufacturing the membrane reactor is expensive, after considering the carbon tax factor, it actually is more economically preferable compare with the traditional Pressure Swing Adsorption (PSA) process. Most research on Pd membrane technology has been conducted at lab scale; nonetheless, the contribution of a palladium membrane technology to economic and societal development requires its commercialization, diffusion and utilization. To generate enough incentives for commercialization, it is necessary to demonstrate the scalability and robustness of the membranes in industrial settings. Consequently, a multitube membrane module suitable for IGCC system was designed and manufactured and sent to National Carbon Capture Center (NCCC) for testing. This work developed a Computational Fluid Dynamics (CFD) model for the module and validated the model utilizing the pilot-scale experimental data generated under industrial conditions. The model was then up-scaled and used to determine the intrinsic phenomena of palladium membrane scale up. This study reveals the technical/engineering requirements for the effective design of large-scale multitube membrane modules. Mass transfer limitations and concentration polarization effects were studied quantitatively with the developed model. Methods for diminishing the concentration polarization effect were proposed and tested through the simulations such as i) increasing convective forces and ii) designing baffles to create gas recirculation. For scaled-up membrane modules, mass transfer limitation is an important parameter to consider as large modules showed severe concentration polarization effects. IGCC systems produce H2 from coal combustion; other ways of H2 production include steam-reforming processes, using natural gas or bio-ethanol as the reactant. The product contains a mixture of H2, CH4, CO, CO2 and steam. Thus, steam-reforming processes are often followed by a Pressure Swing Adsorption (PSA) unit in order to obtain pure hydrogen. Palladium membrane, on the other hand, can be integrated with steam-reforming processes and achieve the simultaneous production and purification of H2 in a single unit by reaching process intensification. Higher H2 production rate can be reached by process intensification as one of the products H2 is constantly being removed. Temperature control is a very important topic in steam reforming processes, as the reaction is overall highly endothermic; although implementing an in-unit membrane improves H2 production rate, it also makes the temperature control more difficult as the reaction equilibrium is altered by the removal of one of the products H2. Hereby, an experimental study of catalytic membrane reactor (CMR) was carried out along with both isothermal and non-isothermal CFD simulations that are validated by the experimental data in order to visualize the temperature distribution inside the reactor and understand the influence of the operating conditions including temperature, pressure and the sweep gas flow patter on the permeate side.

Hydrogen (H2) represents an energy carrier endowed with the potential to contribute to the design of a robust and reliable global energy system by complementing electricity as well as liquid fuels use in an environmentally responsible manner provided that the pertinent H2 production technologies (conventional and new ones) can reach techno-economically attractive performance levels in the presence of irreducible (macroeconomic, fuel market, regulatory) uncertainty. Indeed, the role of H2 in the global energy economy is widely recognized as significant in light also of fast-growing demand in the petrochemical and chemical processing sector as well as future regulatory action on greenhouse gas emissions. Pd and Pd/Alloy-based catalytic membrane reactor (CMR) modules potentially integrated into H2 production (HP-CMR) process systems offer a promising technical pathway towards H2 production with enhanced environmental performance in a carbon-constrained world. However, the lack of accumulated operating experience for HP-CMR plants on the commercial scale poses significant challenges. Therefore, any preliminary attempt to assess their economic viability is certainly justified. A comprehensive techno-economic performance assessment framework has been developed for HP-CMRs with CO2 capture capabilities. A functional Net Present Value (NPV) model has been developed first to evaluate the economic viability of HP-CMRs. The plant/project value of HP-CMR is compared to other competing technology options such as traditional coal-gasification and methane steam reforming-based hydrogen production plants with and without CO2 capture. Sources of irreducible uncertainty (market and regulatory) as well as technology risks are explicitly recognized and the effect of these uncertainty drivers on the plant’s/project’s value is taken into account using Monte-Carlo techniques. Therefore, more realistic distribution profiles of the plant’s economic performance outcomes are generated rather than single-point value estimates. It is shown that future regulatory action on CO2 emissions could induce appealing NPV-distribution profiles for HP-CMRs in the presence of uncertainty and technology risks. Finally, the valuation assessment is complemented with a sensitivity analysis for different representative values of the discount rate that span a reasonable range associated with business and financing risks. It apparently indicates that creatively structured financing mechanisms leading to a reduction of the cost of capital/discount rate could induce more appealing economic performance outcomes and valuation profiles. Furthermore, the proposed research work aims at the development of a methodological framework to assess the economic value of flexible alternatives in the design and operation of HP-CMR plants with carbon capture capabilities under the aforementioned sources of uncertainty. The main objective is to demonstrate the potential value enhancement associated with the long-term economic performance of flexible HP-CMR project investments by managing the uncertainty associated with future environmental regulations. Within the proposed context, promising design flexibility concepts for HP-CMR plants are introduced and operational as well as constructional flexibility options are identified and assessed. In particular, operational flexibility will be realized through periodic and temporary shutdowns of the carbon capture unit in response to regulatory uncertainties. Constructional flexibility will be realized by considering the installation of a carbon capture unit at three strategic periods: 1) installation in the initial design phase, 2) retrofitting at a later stage and 3) retrofitting with preinvestment. Monte Carlo simulations and financial analysis will be conducted in order to demonstrate that, in the presence of irreducible uncertainty, design flexibility options could lead to economic performance enhancement of HP-CMR plants by actively responding to the above sources of uncertainty as they get resolved over the plant’s lifetime.