Stable operation of 10,000 cubic meter-scale unit for producing syngas via autothermal reforming of methane and carbon dioxide

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A 10,000 cubic meter-scale facility for producing syngas through the autothermal reforming of methane and carbon dioxide has achieved stable operation. Author/Source: Date: 2017-08-14; Clicks: 19. Recently, the facility for producing syngas via the autothermal reforming of methane and carbon dioxide has been operating stably at the coal-to-oil plant of Shanxi Lu’an Group. Building on previous trial operations and system optimizations, the facility was put into full operation on June 21, reached full production capacity on July 10, and completed the on-site calibration organized by the China Petroleum and Chemical Industry Federation on August 2. As of the time of writing, the device has been operating stably for over 1,000 hours, producing more than 20 Nm3 of product gas per day with a low H2/CO molar ratio, and converting up to 60 tons of CO2 per day. 　　The technology for producing syngas through methane and carbon dioxide reforming originated from the methane and carbon dioxide reforming project jointly initiated by the Shanghai Institute of Advanced Study of the Chinese Academy of Sciences, Shanxi Lu’an Mining (Group) Co., Ltd., and Shell Oil Company of the Netherlands. This research project has received support from the **National Natural Science Foundation, key projects funded by the Shanghai Science and Technology Commission, the Strategic Priority Program of the Chinese Academy of Sciences – Coal-related projects, **science and technology support programs, and **key research and development initiatives. Through initial in-depth research on the mechanisms of catalyst deactivation, the research team made significant progress in terms of the catalyst’s stability against carbon deposition; the catalysts developed were able to operate stably for over 5,000 hours under simulated operating conditions. With the support of the CAS Strategic Priority Program on Coal and the **Key Research and Development Program on Nanotechnology, the research team completed the development of catalysts, conducted reactor simulation studies, and carried out the engineering scale-up and production of catalysts in the hundred-ton range. With the support of Shanxi Lu’an Group, they built and operated a facility on a ten-thousand-square-meter scale. 　　CO2 and CH4 are typical greenhouse gases as well as important carbon-containing resources. Using CO2 and CH4 as carbon sources, they can be converted into syngas (CO and H2) under certain conditions; this process is known as methane-carbon dioxide reforming or dry reforming. Compared to traditional methane steam reforming, methane carbon dioxide reforming consumes almost no water; instead, it makes extensive use of carbon dioxide, thereby reducing energy consumption and easing the pressure to cut greenhouse gas emissions, which has earned it widespread attention worldwide. However, this reaction process is particularly prone to carbon deposition, and anti-carbon-deposition catalysts as well as specialized reactors are recognized as the key challenges in bringing this technology to industrial application. Therefore, relevant domestic and international research and development has not yet reached the scale of industrial pilot plants or demonstrations. As Dr. Zhang Jun said, the Key Laboratory of Low-Carbon Transformation Science and Engineering at the Shanghai Advanced Institute has successfully resolved the issue of the stability of nanometal materials, particularly with regard to the matching between the catalyst structure and its internal architecture. Such nanomesh pore catalysts possess the dual functions of resisting carbon deposition and sintering; meanwhile, an optimal match between the structure of the reactor and the catalyst is another important factor for success. On this basis, this technology can be extended to water vapor reforming and multi-reforming applications, enabling flexible adjustment of the H2/CO ratio in syngas (0.7–2.0). Therefore, this technology is suitable for the conversion and utilization of conventional or unconventional natural gas (offshore natural gas rich in CO2, shale gas), as well as for the utilization of off-gases from the coal chemical and metallurgical industries. 　　On August 2, the China Petroleum and Chemical Industry Federation conducted a 72-hour continuous operation calibration of the key technologies for producing syngas through the autothermal reforming of methane and carbon dioxide, as well as the industrial pilot plant developed jointly by the Shanghai Institute of Advanced Technology under the Chinese Academy of Sciences, Shanxi Lu’an Mining (Group) Co., Ltd., and the Dutch company Shell Oil Industries. The expert group listened to reports on the key technologies for the autothermal reforming of methane and carbon dioxide, as well as on the construction, operation, and calibration preparation of the industrial pilot plant carried out by the project contractor; it inspected the actual operation on site, finalized the calibration plan, and confirmed the measuring instruments, analytical equipment, methods, and the calculation procedures for various calibration parameters. During the calibration period, the expert team inspected on-site the operational status of key systems such as the on-site conversion furnace, reviewed the original data records, and examined each area including the control room, analysis room, and on-site sampling sites to ensure that the calibration data were accurate and reliable. Experts unanimously agree that this research has developed high-performance, efficient nanonickele-based catalysts and specialized reactors, optimized the process system, and built the world’s first industrial pilot plant for the autothermal reforming of methane and carbon dioxide to produce syngas on a scale of 10,000 Nm3/h, which is now operating stably. This approach enables the efficient utilization of CO2 as a resource and allows for flexible adjustment of the composition of the product gas, H2/CO; they recommend that industrial application and deployment of this technology be carried out as soon as possible. 　　Sun Yuhan, the project leader at the Shanghai Institute of Advanced Technology affiliated with the Chinese Academy of Sciences, said that the large-scale methane and carbon dioxide reforming technology possesses entirely independent intellectual property rights, with the key lying in the development of efficient catalysts and reactors. The stable operation of this device is a typical example of the transition from fundamental research to engineering demonstration, and it is also the result of successful cooperation between the Shanghai Advanced Research Institute, Shanxi Lu’an Mining (Group) Co., Ltd., and Dutch Shell Oil Company. This technology not only lays an important technical foundation for the large-scale utilization of CO2-rich natural gas, but also brings about significant innovations in the low-carbon development of Shanxi’s coal chemical industry. 　　Li Jinping, chairman of Shanxi Lu’an Group, said that the successful development of the technology for producing syngas through the reformation of methane and carbon dioxide, along with the stable operation of the related facilities, has paved the way for reducing carbon dioxide emissions and making use of this gas as a resource. This significant technological breakthrough is the result of Lu’an Group’s earnest implementation of the five key development concepts and the strategic vision for an energy revolution. It reflects the group’s efforts to carry out high-level, international cooperation in line with the strategic plans set by the Shanxi Provincial Party Committee and government, which focus on innovation-driven development, transformation and upgrading, and taking the lead in the energy revolution. It represents yet another excellent example of integrating industry, academia, research, and practical application. 　　The stable operation of the syngas production facility that uses methane and carbon dioxide for reforming is another typical example of the Shanghai Institute of Advanced Technology under the Chinese Academy of Sciences actively fulfilling the requirements of the \"Four Firsts\" strategy. By focusing on strategic needs and cutting-edge technologies, it explores joint innovation with large domestic and international enterprises. It also represents an innovative model in which R&D centers are located in Shanghai, demonstration sites exist across the country, and commercialization takes place worldwide, adding new highlights to the development of Shanghai as a globally influential science and technology hub. 　　Currently, the three collaborating parties are conducting a commercial assessment of this technology, and have reached an agreement on its global commercial deployment.