Kinetics Model Development and Experimental Scale-up of Cargen® Technology from Milligram Scale to Multi-Kilogram Scale | AIChE

Kinetics Model Development and Experimental Scale-up of Cargen® Technology from Milligram Scale to Multi-Kilogram Scale


Conference Presentation

Conference Type

AIChE Spring Meeting and Global Congress on Process Safety

Presentation Date

March 25, 2024


32 minutes

Skill Level




Dry reforming of methane (DRM) offers an avenue for converting carbon-dioxide (CO2) and methane (CH4), the two major greenhouse-gases, into syngas— a vital chemical precursor. However, DRM is constrained by high energy-demands, catalyst-deactivation, and an unfavorable H2/CO ratio. Previously, a unique dual-reactor system that produces multi-walled carbon nanotubes (MWCNTs) and syngas as products was proposed that offers at least 65% CO2 conversion at 50% the energy demands of DRM. The present study experimentally proves and scales the concept from milligram scale to multi-gram scale and finally to multi-kilogram scale of MWCNT production. This study also introduces and experimentally validates a lumped Langmuir-Hinshelwood-Haugen-Watson (LHHW) kinetics model capturing a network of nine-primary-reactions involving CO, O2, H2, CH4, CO2, H2O, and solid carbon. At milligram scale, the model performs within 5% error-margin for carbon-formation rate at 550°C. At multi-gram scale, the model is validated at 500, 550, and 600°C to capture temperature effect. At this scale, the CH4-conversion and CO2-conversion predictability is within 8% and 30% error-margin respectively. At multi-kilogram scale, the model predicts carbon-formation rate within 21% error-margin at 550°C. Finally, characterization of the MWCNTs using Raman, SEM, TEM, STEM, and TGA-DTA confirms MWCNT quality consistency at all the scales.

In this presentation, we will highlight the unique journey of the scale-up of the CARGEN® process from milligram-scale to multi-kilogram scale demonstrating its readiness for commercial implementation for the large-scale decarbonization and bulk MWCNT production.


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