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INSTITUTE OF PHYSICS PUBLISHING JOURNAL OF PHYSICS D: APPLIED PHYSICS

J. Phys. D: Appl. Phys. 34 (2001) 2798–2803 PII: S0022-3727(01)23229-X

Syngas production via methane steam


reforming with oxygen: plasma reactors
versus chemical reactors
Jean Marie Cormier1 and Iulian Rusu2
1
GREMI, Universite´ d’Orleans,´ 14 rue d’Issoudun, BP 6744-45067, Orleans´ Cedex 2, France
2 Faculty of Industrial Chemistry, Technical University ‘Gh Asachi’,

Bd Dimitrie Mangeron 71, Iasi 6600, Romania


E-mail: jean-marie.cormier@univ-orleans.fr

Received 22 March 2001, in final form 8 July 2001


Published 5 September 2001
Online at stacks.iop.org/JPhysD/34/2798
Abstract
Steam reforming with oxygen (SRO) is a combination of non-catalytic
partial oxidation and steam reforming of methane, industrially used for
syngas production. There are several models of the chemical reactors used
for this purpose but in the last decade a new direction has developed—
plasma devices. The aim of the present paper is to make a comparative
analysis between the autothermal reformers, including their improved
variants, and the plasma reactors. The study is conceived in terms of
advantages and disadvantages coming from the exploitation parameters,
methane conversion, selectivity, energy efficiency and investment costs.
Although SRO by means of chemical reactors may be the most efficient,
plasma reactors represent an incisive approach by their simplicity,
compactness and low price.

1. Introduction production of hydrogen for automotive applications [1, 2].


Syngas is also the main source of carbon monoxide, which is
Synthesis gas or syngas is a mixture of hydrogen and carbon used in an expanding list of carbonylation reactions.
monoxide used as a major intermediary for the production of Originally, coal was the primary source of carbon for
pure hydrogen or other chemical compounds. Among these syngas, but today natural gas has replaced it for economic
we have to mention ammonia with its inestimable utility for reasons. Despite the fact that coal reserves are large and the
industry and agriculture and the liquid products derived by price of coal is lower than that of the hydrocarbons, the
the process known as SCL (syngas conversion to liquids) investment in a coal-based syngas plant is about three times
(e.g. methanol and other alcohols, solvents, diesel fuel, jet higher than that required for a natural-gas-based plant [3].
fuel, gasoline, etc). However, there are also technologies producing syngas from
The growing demand for chemicals derived from syngas petroleum coke, heavy residuals and even biomasses [4, 5].
has led to the development of several technologies (e.g. Natural gas can be processed by several methods, e.g.
Fischer–Tropsch synthesis, NH3 or oxygenate production). partial oxidation with oxygen (PO), steam reforming (SR),
These processes are of strategic importance for any country. For steam reforming with oxygen (SRO), CO2 reforming (CDR)
example, the synthesis developed by Fischer and Tropsch was and CO2 reforming with oxygen (CDRO) [6]. One of the most
used by the Germans during the Second World War to produce attractive technologies seems to be the SRO, which is also
fuel from coal. South Africa also produced fuel this way during known as autothermal reforming. The main reasons for
the political sanctions against the apartheid regime. Today, as recommending this technology over the other variants are the
the fuels obtained from syngas do not contain sulphur or low energy requirements, the high space velocity (at least one
nitrogen compounds, their combustion in engines leads to order of magnitude relative to traditional SR), a lower process
reduced environmental pollution. Hydrogen itself was taken temperature than PO and the H2/CO ratio is easily regulated by
into account in the last period as a clean fuel, important steps the inlet gas ratio [7–9]. The process can be performed by
being made in the research in recent years on the on-board means of various reactor models including plasma reactors.

0022-3727/01/182798+06$30.00 © 2001 IOP Publishing Ltd Printed in the UK 2798


Syngas production with SRO: plasmas or chemicals

If syngas processing is of strategic importance, research However, since a plasma is a mixture of electrons, highly
regarding the use of plasma reactors has also become strategic excited atoms and molecules, ions, radicals, photons, etc, the
for different countries. For example, Germany, Japan and the chemistry is very complex and the present understanding of it is
USA employ large funding regarding automotive applications quite limited. It is difficult to predict theoretically the final
of plasma reactors. The Russian Federal R&D programme in products and their concentration. Unfortunately, most practical
the field of hydrogen energy and technology for the period achievements are based on experiments.
1994–96 also included in the eight most promising processes
for the production and use of hydrogen two concerning plasma- 3. Other methods of syngas production
chemical technologies [10].
Therefore, the aim of the present paper is to make a There is an entire literature concerning the chemical
comparative analysis of the chemical and plasma reactors technologies used or proposed for syngas production.
used for SRO, in order to estimate the real prospects for Therefore, in this section we shall briefly summarize only
plasma processes in this field. reports on syngas production by means of plasma methods.
The plasmatron experiments performed at Michigan
2. Syngas production by SRO Institute of Technology (MIT) on the PO of methane
revealed that for energy inputs of less than 25 MJ kg−1 CH4,
SRO is a combination of non-catalytic partial oxidation and hydrogen output reaches 38% of equilibrium levels and the
steam reforming developed by Haldor Topsøe in the late CO output is 65% of equilibrium [14]. In these conditions
1950s in order to perform reforming in a single reactor [9]. the resulting energy cost was as high as 267 MJ kg−1 H2
There are probably five main chemical reactions in the because most of the hydrogen turns into water.
reforming process: Czernichowski et al used a gliding arc installation for this
process with a similar energy cost [15–17].
Chapelle et al have used a classic gliding arc reactor for
CH4 + H2O ⇔ CO + 3H2 H298 = 206 kJ (1) syngas generation by SR [18]. For an electric power of 1.4
kW and a steam-to-methane ratio of 2–4, the maximum CH4
CH4 + 2H2O ⇔ CO2 + 4H2 H298 = 164.9 kJ (2)
conversion was 44%, with an output energy efficiency of
CH4 + O2 ⇔ CO2 + 2H2 H298 = −318.9 kJ (3) 33% at an energy cost of about 97 MJ kg−1 H2.
CDR is currently of great interest both for the
2CH4 + O2 ⇔ 2CO + 4H2 H298 = −71.8 kJ (4)
transformation of natural gas and for environmental control.
CO + H2O ⇔ CO2 + H2 H298 = −41 kJ. (5) Chapelle et al [18] has performed the reaction in both
Partial oxidation is an exothermic process, while steam transferred arc and gliding arc reactors. In the first case the
reforming is endothermic. The thermal energy generated by the hydrogen concentration in the exit gases decreased from 48
former can be adjusted by its molar air/methane ratio so that the to 22% for a CO2/CH4 ratio increasing from 0.5 to 2. The
overall autothermal process can be carried out without an extra necessary energy for the production of 1 kg of hydrogen was
external heat source for the SR process. Classic thermodynamic of 234 MJ, corresponding to an energy efficiency of about
analysis performed by Chan and Wang 27%. In the second case the energy cost decreased to 226 MJ
[11] indicated that the optimal operating regime is with an kg−1 H2, with an energy efficiency of about 31%. The same
air/methane molar ratio of 3.5 and a 2.5 to 4 water/methane reaction was performed by means of glow discharges, micro-
molar ratio. Under these operating conditions, the number of arc plasmas and dielectric-barrier discharges, but with low
moles of hydrogen per mole of natural gas consumed is energy efficiency [19, 20].
2.19–2.22. The results also showed that under these The advantage of oxygen addition in the CDRO process is
conditions, the solid carbon is suppressed, the mole fraction the supply of additional energy for methane conversion, due to a
parallel reaction of methane oxidation. Laboratory-scale
of CO ranges from 2.24–4.38%, the methane conversion rate experiments gave 100% conversion but at a very high energy
is 99.04– 99.45% and the operating temperature is between −1
expenditure (190–270 MJ kg H2), the energy efficiency
820 and 871 K.
ranging between 23 and 42% [17]. In order to promote an
Taking into account the use of plasma reactors, Bromberg efficient reforming process, Fridman’s team has used a pulsed
and co-workers [12] have simulated the homogeneous SRO corona discharge reactor with preheating of the inlet gases at
process (CH4 + 0.5O2 + 1.88N2 + H2O) by means of non- ◦
about 900 C [21]. They succeeded in lowering the plasma
equilibrium thermodynamics [13]. This method has been used −1
energy cost to 34 MJ kg H2. However, the energy spent for
to determine the reaction trajectory in an adiabatic reactor. The −1
calculations performed for initial temperatures of 500, 1500 and preheating the mixture was about 340 MJ kg H2.
2000 K indicate that the reaction is characterized by two distinct The literature also presents results regarding the use of
stages. During the first stage, complete thermal plasmas for syngas production starting from gasoline
combustion of part of the methane occurs, producing mainly and diesel fuel, biofuels (canola and corn oil) and even used
CO2 and water, increasing the temperature of the system. In tires [22, 23].
the second stage, the remaining methane reacts with CO2
and H2O producing syngas and decreasing the system’s 4. Chemical reactors
temperature. The calculated rate of methane conversion
ranged between 97.5 and 100%, leading to a final hydrogen The reformer basically consists of a ceramic lined tube and a
mole fraction of about 35% and for the CO 8–16%. Ni-based fixed catalyst bed for equilibration of the gas

2799
J M Cormier and I Rusu

(figure 1(a)). The preheated feed streams (CH4 + H2O and H2O with separation of oxygen. Air and methane are introduced
+ O2) are mixed in a burner placed at the top where partial into opposite sides of the membrane, the oxygen dissociated
oxidation of the methane occurs. The final steam reforming into ions diffuses through the membrane reacting with
takes place in the catalyst bed below the burner. Typically, the methane to give oxidation products.
SRO reactor operates at about 2200 K in the combustion zone Air Products, the US Department of Energy, Ceramatec and
and 1200–1400 K in the catalytic zone. Operating pressures other partners have developed a similar reactor technology [34,
range from 12 to 70 atm. Tests carried out on fixed bed reactors 35]. The laboratory-scale apparatus has operated with methane
revealed that one of the most important features concerns the at 7–30 atm and an air feed to the interior membrane at
adiabatic working conditions. Methane conversions up to 90% atmospheric pressure. In the second phase, an engineering
with residence times of up to 0.1 s have been found. process development unit will test subscale membranes under
3
Exxon developed a fluidized-bed system in which the full operating conditions at a nominal 700 m per day.
CH4/H2O mixture is fed to the bottom of the reactor and The weak point of the membrane reactors is the mass
oxygen is fed into the middle of a fluidized bed of catalyst transfer, which is limited if the membrane does not have
(figure 1(b)). The fluidized bed offers the advantage of an sufficient flux to satisfy the productivity of the catalyst.
optimal temperature distribution, with the absence of radial and Other practical issues, such as membrane pore blockage and
axial gradients and a lower pressure drop with respect to a fixed thermal and mechanical stability have limited for the
bed operating at the same dimension and space velocity. moment the usefulness of these systems.
The usual catalyst is a Ni catalyst supported on a Variants of the membrane reactors are the solid oxide fuel
cells (SOFC) and, in the last decade, there has been an increased
refractory material containing a variety of promoters. The
additives are potassium and/or calcium alkali ions, which interest in the use of SOFC to produce H2 [1, 36, 37]. The
mainly serve to suppress excessive carbon deposit on the membrane in this case is also an electrode (the anode), made of
porous carbon plates laced with a catalyst. The hydrogen
catalyst [24]. Recent studies show that catalysts based on −
noble metals seem to be more active for SRO [7, 25]. combines with HO ions to produce water vapour and electric
There are several studies presenting comparisons power. Therefore, the chemical energy is converted directly into
between different processes of syngas synthesis and the electricity. On the anode side, the natural gas is first ejected into
a reforming chamber where it draws waste thermal energy from
implied economics [9, 26–30]. The basis of comparisons
rested mainly on four points: raw material consumption, the stack and is converted into H2 and CO. It then flows into the
energy consumption and energy recovery, investments and anode manifold where most of the H2 and CO is oxidized. This
operational costs. The conclusion that one can draw from gas stream is then partly recycled to the reforming chamber
these studies is that autothermal reforming improves the where the resulting water is used as a reagent. On the cathode
steam reforming cost by 10–20%. This means that the side, air is first blown into a heat exchanger where it reaches
investment varies between 750 and 900 euro per N m3 h−1 nearly operating temperature. The air is brought up to the
operating temperature by combustion of the remaining H2 and
and a final hydrogen cost of 0.05–0.08 euro per Nm3.
CO from the anode. The oxygen in the cathode manifold is
The shortcomings of the chemical autothermal converted into an oxygen ion that travels back to the anode. For
reformers concern size, the large investments, the limitations hydrogen users, the CO can be converted by the established
on rapid response, the extreme operating conditions that mode into CO2 and H2 using a shift reactor followed by CO2
limit the lifetime of a reactor, heat management (during the separation.
front end of the catalyst bed as the methane undergoes total For a cell voltage ranging between 0.5 and 0.8 V, the
oxidation), safety and operability. thermodynamic calculations show an efficiency of electricity
Possible improvements of the SRO include the use of and hydrogen generation of about 80% [37]. The system is
membrane technology, the achievement of integrated simple, efficient, tolerant to impurities and uses cheap
autothermal reforming/fuel cell systems and periodically catalysts. Due to the high operating temperatures air
operated fluidized bed reactors. compression is not required. Another advantage is that both
Conventional SRO often leads to low hydrogen yield since hydrogen and CO are used in the cell. While in other cases,
the formed H2 may react with oxygen to yield water. To avoid CO is a poison, in SOFC it is a fuel. Moreover, SOFCs can
this problem several authors have proposed a periodic system provide an effective energy conversion system even for
with a feed composition alternating between CH4/O2 and small-scale plants.
CH4/H2O mixtures [31–33]. It was envisaged that this would Tanaka et al [38] have designed a combined cycle
promote independent methane oxidation and steam reforming system with a solid oxide fuel cell and gas turbine.
steps, and thus minimize hydrogen reconversion. The results According to their economic calculations the total electricity
indicate that under periodic cycling, SRO proceeds via the generation efficiency can rise up to 60–70%. The gas turbine
interaction of entities derived from the dissociative adsorption accounts for the greatest investment input (35%), with the
of CH4 and H2O leading predominantly to CO2 and H2. next highest being the fuel cell module (including the
A membrane reactor combines the separation properties of reformer—23%), followed by the heat exchanger (20%).
a membrane with the performance of a catalytic system (figure Although the unit investment cost is higher than that for a
1(c)). The combined efforts of Amoco, BP Chemicals, Praxair, large-scale coal power plant it can still be considered as a
Sasol and Statoil developed an innovative technology, named competitive alternative for urban areas. However, a cheaper
OTM (oxygen transport membrane) that can convert natural gas reformer would decrease the investment costs.
to syngas with very high selectivity [7]. In this process, a Among the disadvantages we have to mention that the
ceramic perovskite type membrane permits SRO
SOFCs run at temperatures of 800–1000 ◦C and, therefore,
2800
Syngas production with SRO: plasmas or chemicals

CH4 + H2O H2O + O2 Syngas Exhaust


Syngas

Burner Cyclone

Membrane
O2
Catalyst
bed
Catalyst Fluidised
bed bed

Syngas CH4 + H2O


Reactants

(a) (b) (c)

Figure 1. Different kinds of chemical reformers.

(2)
Cathode
W/2
Insulator
Air W

Anode
Cooling water W/2

(1) (4)
(3)
Cooling water
Figure 3. Diagram of a microwave plasmatron.

Reactants in the gap between the electrodes, and the incoming feedstock
gas blows the arc into the arc chamber. The working gas can be
injected directly or tangentially into the gap between elec-
trodes. Applying an external magnetic field can enhance the gas
Syngas rotation. The electrodes are usually made of copper but it is
possible to use some new improved alloys, such as beryllium
Figure 2. Diagram of a thermal plasma reactor.
bronze and tungsten–copper–nickel.
The SRO reaction performed by Bromberg and his team
several minutes of fuel burning is required to reach operating [40] by the means of a plasmatron, without a catalyst, resulted
temperature. This delay is considered to be a shortcoming for in a hydrogen yield of 40% (defined as the ratio of hydrogen
automotive applications. However, most of the cells generate released to hydrogen content in methane) for an input power of
H2 at 1 atm or less and for bulk production this will then require 3.5 kW. At low values of input power, the homogeneous
higher compression to apply the chemical technology [24]. plasma process resulted in low methane conversions (about
3 −1
40%). The device’s productivity was about 4000 m h H2 per
5. Plasma reactors cubic metre of reactor. The minimum power consumption
−1
without heat recovery was about 100 MJ kg H2.
Depending on their energy, temperature and ionic density, Furthermore, in order to decrease this specific power
plasmas are usually classified as either thermal plasmas or consumption a nickel-based catalyst on an alumina support was
non-thermal (non-equilibrium) plasmas. Generally, the used through. The hydrogen yield increased by up to 80%, for
plasma used for chemical applications is required to provide an input power of 2.7 kW and a methane conversion
a high operating power together with a very selective energy rate of 70%. The plasma composition of the reformate was of
input while simultaneously maintaining a non-equilibrium 35%H2, 5%CH4, 3.7%CO, 15%CO2, 41%N2 and traces of C2
condition [15]. hydrocarbons. The required specific energy was reduced to less
−1
Thermal plasma reactors (plasmatrons) have different con- than 17 MJ kg H2. The productivity also increased to about
structive variants (induction, DC and microwave plasmatrons) 3 −1
10 000 m h H2 per cubic metre of reactor.
[18, 39]. Basically, the plasmatron comprises two water-cooled The main drawback of using thermal plasmas is the
metallic tubular electrodes (figure 2). A spark occurs overheating of the reaction media, when the reagents in all

2801
J M Cormier and I Rusu

A no d e s
V1 V2 V3

C a tho d e

G a s o utle t

D isc h a rge s T°
T° M e a su re
Measure C he m ic a l

G a s inle t d ia gno stic s

Figure 4. Diagram of a three-discharge glidarc reactor.

Table 1. Comparative data for SRO reactors.


Investment cost
Investment cost H2 cost SOFC-GT-SRO system
(euro/Nm3 h−1 H2 ) (euro/Nm3) (euro/W)
Chemical reactors 750–900 0.05–0.08 5.12
Plasma reactors 65 0.23 4.59

degrees of freedom uniformly consume energy. It is the high electrons as well as excited ions, atoms or molecules that
electron temperature that determines the reaction evolution promote selective chemical transitions efficiently. Such a
in non-thermal plasmas, while the gas temperature can gliding arc occurs when the plasma is generated between two
remain as low as room temperature. Non-thermal plasmas or more diverging electrodes placed in a fast gas flow [46].
have several types if discharge: glow, corona, dielectric The average residence time of the reagents in the reaction
barrier, microwave, radiofrequency and gliding arc [41, 42]. zone is about 10−3 s. This fact allows very high specific
The microwave discharge operates at very high throughputs in the reaction zone, which generally exceed, by
frequencies, with which only light electrons can follow the four orders of magnitude, other chemical methods, including
oscillations of the electric field. Therefore, this discharge is electrochemical and thermal ones. The literature presents
far from local thermodynamic equilibrium and has the several studies modelling the behaviour of glidarcs trying to
advantage that it can be used in a wide pressure range. predict the working parameters in different experimental
The electron temperatures in a microwave discharge are conditions [47–53].
mainly defined by the electric field (Eel ) in the discharge The electrical circuit of a gliding arc consists of a high
and by the pressure (P ); however the maximization of the voltage generator (up to 10 kV) used to ignite the discharge
Eel /P ratio at the discharge axis may be sufficient for and a second power generator with a voltage up to 1 kV and
electrodynamic stabilization [43]. This can be achieved by a total current up to 10 A. Current limitation is achieved by
the interference of microwaves. Practically, the radiation is means of inductance.
introduced into the microwave device along a waveguide The experiments for generating syngas by SRO in gliding
(1), the power W being divided into two identical coherent arc reactors have only been performed in the laboratory.
components (W/2) by means of a metal pin (2) mounted in a Researchers from GREMI, Universite´ d’Orleans,´ have used a
metal cylinder (3) (figure 3). The discharge is formed into a reactor with an inner cone-shaped electrode and an external
dielectric tube (4), Eel taking the highest value in its central metallic tube as a second electrode. This plasma reactor
plane. This is due to the fact that the system is symmetrical generates turning gliding arc discharges, produced by the radial
with respect to the electric field. Scientists from Kurchatov injection of the gas mixture. Approximately 40% of the methane
Institute of Moscow have studied the SRO experimentally submits to chemical transformation at a conversion cost of about
−1 −1
(5% oxygen for a ratio H2O/CH4 < 1) using such a 89 MJ kg H2 and to 125 kJ mole of converted methane,
continuous microwave discharge plasmatron [43, 44]. The when a ratio of H2O/CH4 = 4.5 was used through. The electric
discharge power was up to 200 kW, the frequency was 915 power ranged between 0.1 and 0.3 kW with an output energy
MHz, the gas-flow rate up to 200 m3 h−1, and the gas efficiency of 40%. The productivity was as high as 10 000 m
3
pressure in the reaction zone varied in the range 0.1–1 atm. −1 3
h H2 per m of reactor, operating at atmospheric pressure.
In this case the energy consumption was of 42–47 MJ kg−1 Further tests started in Spring 2001 with a multiple discharge
H2 for a methane conversion rate higher than 90%. reactor (figure 4) using various catalysts.
Quite recently, a simpler alternative approach for plasma We now present some preliminary results concerning the
SRO has been proposed–the gliding arc [15, 45]. In this cold costs of syngas production by means of plasma reformers. There
plasma the ionization processes induced by the electric field are three major costs in the manufacturing of hydrogen-rich gas:
dominate the thermal ones and give relatively high-energy the natural gas cost, the electricity cost and the

2802
Syngas production with SRO: plasmas or chemicals

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