(160a) Conceptualization, Experimental Proof, and Life Cycle Assessment of Cargen™, a Novel CO2 Utilization Technology

Dry Reforming of methane (DRM) has attracted significant scientific attention due to its potential for effective greenhouse gas (methane and carbon dioxide) conversion to ‘syngas.’ Syngas is a mixture of carbon monoxide and hydrogen and is used to produce a variety of chemicals, additives, and synthetic fuels. The commercial implementation of DRM is, however, limited due to three primary process challenges, (a) Carbon formation leading to catalyst deactivation, (b) Syngas ratio adjustment requirement for downstream application, (c) high energy requirement needed to drive the reaction. Our research group has developed and pioneered a novel technological solution, CARGEN™ technology, addressing DRM challenges. The CARGEN™ technology presents a unique and breakthrough advantage of co-producing Carbon Nanotubes (CNTs) as a co-product along with Syngas at an adjustable ratio that can meet downstream process requirements.

Some of the key highlights of CARGENâ„¢ technology’s demonstrated performance are: (a) Ability to convert at least 65% CO₂ at 50% less energy compared to standalone DRM process. (b) Co-production of CNTs and Syngas, which are products of high value and demand. (c) At least 40% reduction in CO₂ footprint and operational costs compared to commercial reforming technologies. (d) A possibility to integrate into existing gas processing infrastructure with an attractive economic and sustainability incentive.

In this presentation, we present the pioneering journey of CARGENâ„¢ technology from its theoretical conceptualization to experimental proof, and to the scale-up from micro-grams of CNT production to multi-grams. The talk will also highlight the results of life cycle assessment (LCA) and a preliminary techno-economic evaluation to demonstrate the sustainability and economics benefits that can be achieved upon implementation of CARGENâ„¢ technology.

This work was a part of a mega-project (NPRP-X 100-2-024), and Responsive Research Seed Grant (RRSG) focused on addressing DRM challenges from micro to macro scale.

References:

1. Challiwala MS, Choudhury HA, Wang D, El-Halwagi MM, Weitz E, Elbashir NO. A novel CO2 utilization technology for the synergistic co-production of multi-walled carbon nanotubes and Syngas. Sci Rep. 2021;11(1):1417. doi:10.1038/s41598-021-80986-2
2. Challiwala MS, Choudhury HA, Sengupta D, El-Halwagi MM, Elbashir NO. Turning CO2 into Carbon Nanotubes. Chem Eng Prog. October 2020:9-10. aiche.org/cep.
3. Elbashir NO, Challiwala MA, Sengupta D, Mahmoud EM. System and method for carbon and syngas production. April 2020.
4. Challiwala M, Afzal S, Choudhury HA, Sengupta D, El-halwagi M, Elbashir NO. Alternative pathways for CO2 utilization for enhanced methane dry reforming technology. In: Advances in Carbon Management Technologies. ; 2019.
5. Challiwala M, Choudhury HA, Elbashir NO. Regeneration & Activation of Dry Reforming of Methane Catalysts Using CO2. 2019.