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Hydrogen production from natural gas using an iron-based chemical looping technology: Thermodynamic simulations and process system analysis

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  • Kathe, Mandar V.
  • Empfield, Abbey
  • Na, Jing
  • Blair, Elena
  • Fan, Liang-Shih

Abstract

Hydrogen (H2) is a secondary fuel derived from natural gas. Currently, H2 serves as an important component in refining operations, fertilizer production, and is experiencing increased utilization in the transportation industry as a clean combustion fuel. In recent years, industry and academia have focused on developing technology that reduces carbon emissions. As a result, there has been an increase in the technological developments for producing H2 from natural gas. These technologies aim to minimize the cost increment associated with clean energy production. The natural gas processing chemical looping technology, developed at The Ohio State University (OSU), employs an iron-based oxygen carrier and a novel gas–solid counter-current moving bed reactor for H2 production. Specifically, this study examines the theoretical thermodynamic limits for full conversion of natural gas through iron-based oxygen carrier reactions with methane (CH4), by utilizing simulations generated with ASPEN modeling software. This study initially investigates the reducer and the oxidizer thermodynamic phase diagrams then derives an optimal auto-thermal operating condition for the complete loop simulation. This complete loop simulation is initially normalized for analysis on the basis of one mole of carbon input from natural gas. The H2 production rate is then scaled to match that of the baseline study, using a full-scale ASPEN simulation for computing cooling loads, water requirements and net parasitic energy consumption. The full scale ASPEN simulation is used to analyze the thermal efficiency of multiple energy recovery schemes, for further validation of the chemical looping process. Resulting from this study, the chemical looping technology is found to produce a cold gas efficiency improvement of more than 5 percentage points and an effective thermal efficiency of more than 6 percentage points over the conventional steam methane reforming process, while producing H2 from natural gas with greater than 90% carbon capture.

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  • Kathe, Mandar V. & Empfield, Abbey & Na, Jing & Blair, Elena & Fan, Liang-Shih, 2016. "Hydrogen production from natural gas using an iron-based chemical looping technology: Thermodynamic simulations and process system analysis," Applied Energy, Elsevier, vol. 165(C), pages 183-201.
    • Handle: RePEc:eee:appene:v:165:y:2016:i:c:p:183-201
    DOI: 10.1016/j.apenergy.2015.11.047
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    11. Chávez-Rodríguez, Mauro F. & Dias, Luís & Simoes, Sofia & Seixas, Júlia & Hawkes, Adam & Szklo, Alexandre & Lucena, Andre F.P., 2017. "Modelling the natural gas dynamics in the Southern Cone of Latin America," Applied Energy, Elsevier, vol. 201(C), pages 219-239.
    12. Abdul Rahim Shaikh & Qinhui Wang & Long Han & Yi Feng & Zohaib Sharif & Zhixin Li & Jianmeng Cen & Sunel Kumar, 2022. "Techno-Economic Analysis of Hydrogen and Electricity Production by Biomass Calcium Looping Gasification," Sustainability, MDPI, vol. 14(4), pages 1-22, February.
    13. Sun, Zhao & Chen, Shiyi & Hu, Jun & Chen, Aimin & Rony, Asif Hasan & Russell, Christopher K. & Xiang, Wenguo & Fan, Maohong & Darby Dyar, M. & Dklute, Elizabeth C., 2018. "Ca2Fe2O5: A promising oxygen carrier for CO/CH4 conversion and almost-pure H2 production with inherent CO2 capture over a two-step chemical looping hydrogen generation process," Applied Energy, Elsevier, vol. 211(C), pages 431-442.
    14. Nadgouda, Sourabh G. & Guo, Mengqing & Tong, Andrew & Fan, L.-S., 2019. "High purity syngas and hydrogen coproduction using copper-iron oxygen carriers in chemical looping reforming process," Applied Energy, Elsevier, vol. 235(C), pages 1415-1426.
    15. Xiang, Dong & Huang, Weiqing & Huang, Peng, 2018. "A novel coke-oven gas-to-natural gas and hydrogen process by integrating chemical looping hydrogen with methanation," Energy, Elsevier, vol. 165(PB), pages 1024-1033.
    16. Kang, Dohyung & Lim, Hyun Suk & Lee, Minbeom & Lee, Jae W., 2018. "Syngas production on a Ni-enhanced Fe2O3/Al2O3 oxygen carrier via chemical looping partial oxidation with dry reforming of methane," Applied Energy, Elsevier, vol. 211(C), pages 174-186.
    17. Liu, Xiangyu & Hong, Hui & Zhang, Hao & Cao, Yali & Qu, Wanjun & Jin, Hongguang, 2020. "Solar methanol by hybridizing natural gas chemical looping reforming with solar heat," Applied Energy, Elsevier, vol. 277(C).
    18. Shareq Mohd Nazir & Olav Bolland & Shahriar Amini, 2018. "Analysis of Combined Cycle Power Plants with Chemical Looping Reforming of Natural Gas and Pre-Combustion CO 2 Capture," Energies, MDPI, vol. 11(1), pages 1-13, January.
    19. Zhang, Yitao & Wang, Dawei & Pottimurthy, Yaswanth & Kong, Fanhe & Hsieh, Tien-Lin & Sakadjian, Bartev & Chung, Cheng & Park, Cody & Xu, Dikai & Bao, Jinhua & Velazquez-Vargas, Luis & Guo, Mengqing & , 2021. "Coal direct chemical looping process: 250 kW pilot-scale testing for power generation and carbon capture," Applied Energy, Elsevier, vol. 282(PA).
    20. Surywanshi, Gajanan Dattarao & Patnaikuni, Venkata Suresh & Vooradi, Ramsagar & Anne, Sarath Babu, 2021. "4-E and life cycle analyses of a supercritical coal direct chemical looping combustion power plant with hydrogen and power co-generation," Energy, Elsevier, vol. 217(C).
    21. Dianju Wang & Zhandong Li & Haixiang Zhang & Shufen Liu & Fahao Yu & Ji Li & Xingbin Liu & Yingjian Xiao & Yunshu Lv, 2023. "Evaluation of the Performance of a Composite Water Control Process for Offshore Bottom Water Fractured Gas Reservoirs," Energies, MDPI, vol. 16(18), pages 1-11, September.
    22. Esteban-Díez, G. & Gil, María V. & Pevida, C. & Chen, D. & Rubiera, F., 2016. "Effect of operating conditions on the sorption enhanced steam reforming of blends of acetic acid and acetone as bio-oil model compounds," Applied Energy, Elsevier, vol. 177(C), pages 579-590.
    23. Hua, Xiuning & Fan, Yiran & Wang, Yidi & Fu, Tiantian & Fowler, G.D. & Zhao, Dongmei & Wang, Wei, 2017. "The behaviour of multiple reaction fronts during iron (III) oxide reduction in a non-steady state packed bed for chemical looping water splitting," Applied Energy, Elsevier, vol. 193(C), pages 96-111.
    24. Jida Zhang & Liguo Yang, 2024. "Aspen Simulation Study of Dual-Fluidized Bed Biomass Gasification," Energies, MDPI, vol. 17(10), pages 1-21, May.
    25. Xiang, Dong & Zhou, Yunpeng, 2018. "Concept design and techno-economic performance of hydrogen and ammonia co-generation by coke-oven gas-pressure swing adsorption integrated with chemical looping hydrogen process," Applied Energy, Elsevier, vol. 229(C), pages 1024-1034.

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