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

Author

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

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.

Suggested Citation

  • Pascual, S. & Barón, C. & Katla, D. & Skorek-Osikowska, A. & Węcel, D. & Bailera, M. & Legaz, J. & Peña, B. & Lisbona, P., 2025. "Pilot-plant experimental tests and kinetic model validation of Ru-based catalytic methanation: assessment of operating pressure and filler material on carbon conversion," Energy, Elsevier, vol. 335(C).
    • Handle: RePEc:eee:energy:v:335:y:2025:i:c:s0360544225038253
    DOI: 10.1016/j.energy.2025.138183
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    References listed on IDEAS

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    1. Bailera, Manuel & Lisbona, Pilar & Romeo, Luis M. & Espatolero, Sergio, 2017. "Power to Gas projects review: Lab, pilot and demo plants for storing renewable energy and CO2," Renewable and Sustainable Energy Reviews, Elsevier, vol. 69(C), pages 292-312.
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