This work describes the application of porous metal supported Pd-membranes to the water-gas shift catalytic membrane reactor in the context of its potential application to the Integrated Gasification Combined Cycle (IGCC) process. The objective of this work was to develop a better understanding of Pd-membrane fabrication techniques, water-gas shift catalytic membrane reactor operation, and long-term behavior of the Pd-membranes under water-gas shift conditions. Thin (1.5 - 16 um) Pd-membranes were prepared by electroless deposition techniques on porous metal supports by previously developed methods. Pd-membranes were installed into stainless steel modules and utilized for mixed gas separation (H2/inert, H2/H2O, dry syngas, and wet syngas) at 350 - 450C and 14.5 atma to investigate boundary layer mass transfer resistance and surface inhibition. Pd-membranes were also installed into stainless steel modules with iron-chrome oxide catalyst and tested under water-gas shift conditions to investigate membrane reactor operation in the high pressure (5.0 - 14.6 atma) and high temperature (300 - 500C) regime. After the establishment of appropriate operating conditions, long-term testing was conducted to determine the membrane stability through He leak growth analysis and characterization by SEM and XRD. Pd and Pd/Au-alloy membranes were also investigated for their tolerance to 1 - 20 ppmv of H2S in syngas over extended periods at 400C and 14.0 atma. Water-gas shift catalytic membrane reactor operating parameters were investigated with a focus on high pressure conditions such that high H2 recovery was possible without a sweep gas. With regard to the feed composition, it was desirable to operate at a low H2O/CO ratio for higher H2 recovery, but restrained by the potential for coke formation on the membrane surface, which occurred at a H2O/CO ratio lower than 2.6 at 400C. The application of the Pd-membranes resulted in high CO conversion and H2 recovery for the high temperature (400 - 500C) water-gas shift reaction which then enabled high throughput. Operating at high temperature also resulted in higher membrane permeance and less Pd-surface inhibition by CO and H2O. The water-gas shift catalytic membrane reactor was capable of stable CO conversion and H2 recovery (96% and 88% respectively) at 400C over 900 hours of reaction testing, and 2,500 hours of overall testing of the Pd-membrane. When 2 ppmv H2S was introduced into the membrane reactor, a stable CO conversion of 96% and H2 recovery of 78% were observed over 230 hours. Furthermore, a Pd90Au10-membrane was effective for mixed gas separation with up to 20 ppmv H2S present, achieving a stable H2 flux of 7.8 m3/m2-h with a moderate H2 recovery of 44%. The long-term stability under high pressure reaction conditions represents a breakthrough in Pd-membrane utilization.

In this work, inorganic membranes with highly dispersed metallic catalysts on macroporous titania-washcoated alumina supports were produced, characterized and tested in a catalytic membrane reactor. The reactor, operated as a contactor in the forced pore-flow-through mode, was used for the conversion of synthesis gas (H2 + CO) into mixed alcohols and hydrocarbons via the Fischer-Tropsch synthesis. Carbon monoxide conversions of 78% and 90% at near atmospheric pressure (300kPa) and 493K were recorded over cobalt and bimetallic Co-Mn membranes respectively. The membranes also allowed for the conversion of carbon dioxide, thus eliminating the need for a CO2 separation interphase between synthesis gas production and Fischer-Tropsch synthesis. Catalytic tests conducted with the membrane reactor with different operating conditions (of temperature, pressure and feed flow rate) on cobalt-based membranes gave very high selectivity to specific products, mostly higher alcohols (C2 – C8) and paraffins within the gasoline range, thereby making superfluous any further upgrading of products to fuel grade other than simple dehydration. Manganese-promoted cobalt membranes were found not only to give better Fischer-Tropsch activity, but also to promote isomerization of paraffins, which is good for boosting the octane number of the products, with the presence of higher alcohols improving the energy density. The membrane reactor concept also enhanced the ability of cobalt to catalyze synthesis gas conversions, giving an activation energy Ea of 59.5 kJ/mol.K compared with 86.9 – 170 kJ/mol.K recorded in other reactors. Efficient heat transfer was observed because of the open channel morphology of the porous membranes. A simplified mechanism for both alcohol and hydrocarbon production based on hydroxycarbene formation was proposed to explain both the stoichiometric reactions formulated and the observed product distribution pattern.

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.