Novel Plasma Catalysis Reformer of CO2 for Power to Jet Fuel and Energy Storage

We have demonstrated a non-thermal atmospheric microwave plasma (AMP) reformer that efficiently reuses CO2 for the generation of low-carbon intensity jet fuel. While other modes of transportation may be electrified, aviation depends on safe, high energy density jet fuels. In Phase IIA, we have exceeded the main goals of the program: greater than 90% methane conversion (achieved ~99%) and greater than 60% electrical efficient (achieved 60%) with systems that are commercial scale. The Technology Readiness Level (TRL) was raised to 5 using a 100 kW system operating at 915 MHz. The experimental results have been used to benchmark the models. In Phase IIA, AMP technology redesigned and scaled up to 50 kW, and tested for short periods of time, limited by thermal management. A pilot-scale unit, operating at 40 kW, is presently being tested in the field at a site of our industrial collaborator. We should be able to perform preliminary tests in this unit before the end of Phase IIA. In Phase IIC, in collaboration with our industrial partner, we intend to upgrade the pilot-scale system with the goal of reaching TRL 6 by the end of the program with the improved reactor design. We will operate at 100 kW and 915 MHz for long duration (weeks). This unit will be pre-commercial scale; increased productivity will be achieved through multiplexing 100 kW units. Limitations from Phase IIA will be addressed to further optimize the AMP operation, including improved thermal management for long duration and high-power (100 kW) testing by using means to drive nonthermal plasmas, such as seeding to control the plasma temperature, and by providing thermal integration to recuperate the heat from the hot CO-rich exhaust to increase electrical efficiency. There is significant demand for low carbon intensity jet fuel, and Fischer-Tropsch (FT) synthesis is an approved pathway. The current supply of sustainable aviation fuel (SAF) is approximately 5 million gallons per year and is forecast to rise to 3 and 35 billion gallons by 2030 and 2050, respectively. Phase IIA techno-economic analysis of the combined AMP and FT synthesis of SAF projects a minimum selling price near the market price of conventional jet fuel with a 50-80 % reduction of carbon dioxide emissions (depending on feedstocks). If the project is successful, the environmental and economic impact is billions of gallons of displaced fossil jet fuel: for every billion gallons displaced, a potential ten million tonnes of CO2 emissions can be reduced.