Enhancing Sabatier Reaction Efficiency with Membrane Reactors

With growing concerns about rising CO₂ levels and their environmental effects, the relevance and opportunity for impact of the Sabatier reaction are increasing. This reaction converts CO₂ and hydrogen into methane, which makes it crucial for carbon utilization and generating sustainable energy. The Sabatier reaction has a unique application for spacecraft fuel generation using cabin air rich in CO₂. Intensified unit operations, like membrane reactors, may improve efficiency by increasing CO₂ conversion at equivalent temperatures, overcoming energy consumption challenges. Considering the membrane reactor as a shell and tube reactor, cabin air is passed through the tube side, H₂ is passed through the shell side, and CO₂ passes through the membrane to the shell side, where the catalyst is packed, and the reaction takes place. A membrane reactor and a traditional packed bed reactor were simulated using AVEVA Process Simulation (APS) in which both carried out the Sabatier reaction and operated with equivalent space time and space velocity. The two methods’ heat duties, capital costs, and operating costs were assessed to compare the viability of the membrane reactor. The respective conversions of the two reactors were obtained with the reactors operating at similar temperatures, H₂/CO₂ feed ratios, and catalyst amounts. Sensitivity analysis was then performed to find the ideal temperature range for identical conversion for the two reactors.