(205a) Thermally and Chemically Stable Metallic Membrane Reactors for H2 generation with CO2 Capture

Precision Combustion, Inc. (PCI) is developing a novel membrane reactor (MR) for high efficiency and cost-effective H2 generation and separation with simultaneous CO2 capture, suitable for integration with modular, fuel-flexible gasifiers and reformers.

A proprietary Pd-alloy with tailored composition was identified and demonstrated to enhance the thermal and chemical stabilities of the membrane when operated with simulated water-gas-shift (WGS) conditions. An ultra-thin (<5 µm), defect-free film was deposited onto porous ceramic supports for maximizing flux. Unlike performance reported for prior field demonstrations, the membrane demonstrated high H2 permeance and recovery of up to 90% over 1,200 hours of testing with simulated WGS conditions. The membrane was subjected to multi thermal and pressure cycles and maintained a H2 purity of >99.9%, suggesting no leak growth or H2 embrittlement after cycling. The observed stability of the membrane was correlated to the membrane composition and improved microstructure/synthesis.

Using the Department of Energy’s (DOE’s) Institute of Design and Advanced Energy Systems (IDAES) resources, we validated a WGS-MR model in Pyomo. By combining the Pyomo model with the H2A model developed by the National Renewable Energy Laboratory (NREL), we performed a preliminary design optimization and technoeconomic analysis (TEA), finding our WGS-MR improved the conversion of feed to H2 by ~22%, resulting in ~14% reduction in levelized cost of H2 (LCOH). We then quantified the impact of the enhanced membrane material properties and identified process integration opportunities to further reduce the LCOH to ~$2/kg H2 (with CO2 capture), ~24% reduction in LCOH vs. the baseline cost.

In future work, PCI will mature the WGS-MR to confirm technical and economic viability of producing high purity H2 from gasified biomass/coal blends. We will also address technology commercialization barriers to transition the technology to fielded applications.