Pilot-plant experimental tests and kinetic model validation of Ru-based catalytic methanation: assessment of operating pressure and filler material on carbon conversion

S. Pascual, C. Barón, D. Katla, A. Skorek-Osikowska, D. Węcel, M. Bailera, J. Legaz, B. Peña and P. Lisbona

Energy, 2025, vol. 335, issue C

Abstract: The production of synthetic methane is crucial for the energy transition in hard-to-electrify industries. This study assesses the reactor filler (Al2O3 and SiC) and operating pressure (1 and 4 bar) effects on methane performance of a commercial Ru-Al2O3 catalyst. Three catalytic methanation parameters are tested over a wide range: temperatures (200–450 °C), gas hourly space velocities (8000–120,000 h−1), and H2/CO2 molar ratios (3.5–5.5). Experiments are conducted in two pilot plants located at the Universidad de Zaragoza and the Silesian University of Technology. Results demonstrate a high level of reproducibility between the two pilot plants, using Al2O3 filler at 1 bar. Additionally, a kinetic model is validated with experimental measurements, showing an error margin of ±5 % between the model and experimental data. Regarding the effects of operational pressure and reactor filler, the best carbon conversion results are obtained with Al2O3 filler at 4 bar (up to 98 %). For both reactors, a 5 % reduction in carbon conversion is observed at 450 °C for SiC filler. Methane selectivity remains above 99 % in all cases, except for SiC filler at 1 bar (90 %). However, SiC filler shows better thermal diffusion, facilitating operational control.

Keywords: Methanation; Hydrogen; Carbon conversion; CO2 utilization; Synthetic natural gas; Ruthenium catalyst (search for similar items in EconPapers)
Date: 2025
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Persistent link: https://EconPapers.repec.org/RePEc:eee:energy:v:335:y:2025:i:c:s0360544225038253

DOI: 10.1016/j.energy.2025.138183

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