Plasma-Assisted Catalysis for CO2 Utilization

The goal of this work is to develop a new technology that uses nonthermal plasma to efficiently convert carbon dioxide and methane, two greenhouses gases, to syngas. Benefits that can be realized with the use of plasma include: (1) operation at low and intermediate temperatures with or without catalysts, (2) on-demand production of syngas, (3) production of syngas having a hydrogen-to-carbon monoxide ratio between 1-3, which is needed to produce higher value chemicals including methanol, acetic acid, formaldehyde and others. In addition, coke formation is a known problem in traditional dry methane reforming. In our plasma reformer, a new approach for decoking is explored. By combining plasma and catalysts, syngas is produced on-demand from feedstocks containing carbon dioxide and methane (natural gas). To support this program, ACT has established partnerships with Lehigh University and a global syngas manufacturer to aide in commercialization. A non-thermal dielectric barrier discharge reactor was developed and tested for converting carbon dioxide and methane to syngas. Laboratory experiments considered the role of several parameters on performance including the effect of: (1) electrical power input, (2) gap height, (3) reactor temperature, (4) dielectric material selection, (5) catalyst selection and (6) nitrogen gas addition. A preliminary scaling analysis was also done comparing the cost per kilogram hydrogen (and syngas) produced using a plasma process as a function of capacity for different electricity costs. The main focus of Phase II is to evaluate proposed options for increasing energy efficiency and scale-up the reactor with support from our industry partner. Syngas is used to synthesize valuable end products including formic acid, acetic acid, polycarbonates, dimethyl ether, and other chemicals. The global annual market size for syngas derived chemicals and fuels is ~$50 billion.