This project is utilizing solid oxide membrane reactors for chemical transformations that are critical to the seamless integration of shale natural gas and liquids into the chemical industry supply chain. The project is particularly interested in the production of propylene from propane. Current propylene production occurs primarily via naphtha steam cracking, a highly energy-intensive process that is not amenable to distributed operations, which are highly desirable when shale natural gas and liquid is used as the carbon source.

This project will utilize microfibrous entrapment of small particulate sorbents or ion exchange (IX) resins to overcome physical barriers and identified technology gaps that currently prevent energy efficient and cost-effective wellhead CO2/CH4 separations through pressure swing adsorption (PSA) and Cs+ removal from nuclear fuel processing streams. Both commercial cyclic adsorption processes are currently limited by heat and mass transport restrictions occurring in large particle (1-4 mm diameter) packed beds.

This project looks to develop both foundational hardware and modeling tools for microwaves as a non-conventional energy input source - a key theme in process intensification - for reactions across chemical conversions and materials synthesis. The project develops scalable microwave technology (MWT) across industries and RAPID focus areas (FAs) and demonstrates its diverse applications with different spatial, temporal, and phase characteristics, often combined with additional process intensification (PI) technologies.

Separation of liquid mixtures, frequently by distillation, consumes large amounts of energy in the chemical and process industries. This project proposes to develop, test, and demonstrate a continuous-flow, scalable, nonthermal, nonequilibrium liquid separation for the test case of ethanol + water that uses ultrasound, and avoids the heat transfer losses and azeotropic bottleneck of distillation. The basis of the separation is straightforward. When ultrasound passes through a nominally quiescent liquid with a free surface above, droplets are produced and form a mist.

Biofuels produced from fermentation processes have long been processed using decades-old distillation technology. Distilling a minor component of this broth to a high purity requires substantial amounts of energy that can lessen the net-energy and profitability of the fuel produced. This work will demonstrate a new technology concept developed by Mattershift, LLC that uses a carbon nanotube (CNT) membrane to selectively extract the biofuel, in this case ethanol, from a fermentation broth.

Renewable feedstocks, including triglycerides and lignocellulose-derived sugars, can be converted to a new class of ionic surfactants, called “oleo-furan sulfonates” (OFS) by multi-step solid acid catalysis. The renewable OFS surfactant exhibits superior properties relative to conventional fossil-derived materials with higher micelle-forming efficiency, stability in cold water, and resistance to hard water.

While tremendous progress has been achieved on creating routes for the production of chemicals and fuels from lignocellulosic biomass, many of these processes are not economic due to the number of process steps required and the requirement for significant inter-stage separations. This project is developing a modularized chemical process intensification technology for the production of bio-para-xylene (biopX) from glucose.

Black liquor (BL), also known as “spent pulping liquor”, is a high-volume byproduct of lignocellulosic biomass pretreatment (i.e., wood pulping by the kraft process). BL is a corrosive, toxic, and complex mixture. About 500 million tons/yr of BL are produced in more than 200 kraft process units worldwide (including 99 in the US, with about 0.2 quads/yr energy spent for BL concentration by multi-effect evaporation). Currently, BL concentration is performed by multi-effect evaporators and is one of the most energy-intensive industrial separation processes.

The rise in US natural gas supplied, tied to challenges/costs associated with natural gas logistics, point to the value of converting natural gas to liquid products. Indirect routes are generally energy inefficient and capital intensive. In contrast, direct non-oxidative natural gas conversion eliminates the syngas production step and required oxygen generation. However, these technologies have not been commercialized because of technical challenges such as low selectivity, coking, heat management, catalyst deactivation and catalyst regeneration.

Throughout the petrochemical and refining industry, the separation of olefins and paraffins is generally performed via distillation, a costly and capital intensive method, particularly for light olefins. This project uses a silver-incorporated custom amorphous fluoropolymer membrane to separate olefins and paraffins. Compared to previous attempts using facilitated transport membranes, this membrane has been shown to have very good longevity in laboratory settings and has been tested with reasonably-expected process poisons.