Methane production through anaerobic digestion of dedicated energy crops

Methane yield of ligno-cellulosic substrates (i.e. dedicated energy crops and agricultural residues) may be limited by their composition and structural features. Hence, biomass pre-treatments are envisaged to overcome this constraint. This thesis aimed at: i) assessing biomass and methane yield of dedicated energy crops; ii) evaluating the effects of hydrothermal pre-treatments on methane yield of Arundo; iii) investigating the effects of NaOH pre-treatments and iv) acid pre-treatments on chemical composition, physical structure and methane yield of two dedicated energy crops and one agricultural residue. Three multi-annual species (Arundo, Switchgrass and Sorghum Silk), three sorghum hybrids (Trudan Headless, B133 and S506) and a maize, as reference for AD, were studied in the frame of point i). Results exhibit the remarkable variation in biomass yield, chemical characteristics and potential methane yield. The six species alternative to maize deserve attention in view of a low need of external inputs but necessitate improvements in biodegradability. In the frame of point ii), Arundo was subjected to hydrothermal pre-treatments at different temperature, time and acid catalyst (with and without H2SO4). Pre-treatments determined a variable effect on methane yield: pre-treatments without acid catalyst achieved up to +23% CH4 output, while pre-treatments with H2SO4 catalyst incurred a methanogenic inhibition. Two biomass crops (Arundo and B133) and an agricultural residue (Barley straw) were subject to NaOH and acid pre-treatments, in the frame of point iii) and iv), respectively. Different pre-treatments determined a change of chemical and physical structure and an increase of methane yield: up to +30% and up to +62% CH4 output in Arundo with NaOH and acid pre-treatments, respectively. It is thereby demonstrated that pre-treatments can actually enhance biodegradability and subsequent CH4 output of ligno-cellulosic substrates, although pre-treatment viability needs to be evaluated at the level of full scale biogas plants in a perspective of profitable implementation.

Catalysts for H2 production

The research of new catalysts for the hydrogen production described in this thesis was inserted within a collaboration of Department of Industrial Chemistry and Materials of University of Bologna and Air Liquide (Centre de Recherche Claude-Delorme, Paris). The aim of the work was focused on the study of new materials, active and stable in the hydrogen production from methane, using either a new process, the catalytic partial oxidation (CPO), or a enhanced well-established process, the steam methane reforming (SMR). Two types of catalytic materials were examined: 1) Bulk catalysts, i.e. non-supported materials, in which the active metals (Ni and/or Rh) are stabilized inside oxidic matrix, obtained from perovskite type compounds (PVK) and from hydrotalcite type precursors (HT); 2) Structured catalysts, i.e. catalysts supported on materials having high thermal conductivity (SiC and metallic foams). As regards the catalytic partial oxidation, the effect of the metal (Ni and/or Rh), the role of the metal/matrix ratio and the matrix formulation of innovative catalysts obtained from hydrotalcite type precursors and from perovskites were examined. In addition, about steam reforming process, the study was carried out first on commercial type catalysts, examining the deactivation in industrial conditions, the role of the operating conditions and the activity of different type of catalysts. Then, innovative materials bulk (PVK and HT) and structured catalysts (SiC and metallic foam) were studied and a new preparation method was developed.

Innovative processes for syngas production

The research of new advanced processes for syngas production is a part of a European project for the production of a new Gas to Liquid Process (NextGTL). The crucial points in the production of GTL process are the energy required for the air separation used in autothermal reforming or the heat required for steam reforming and the efficiency in carbon utilization. Therefore a new multistep oxy-reforming process scheme was developed at lower temperature with intermediate H2 membrane separation to improve the crucial parameter. The process is characterized by a S/C of 0.7 and O2/C of 0.21 having a smoothed temperature profile in which kinetic regime is easily obtained. Active catalysts for low temperature oxy-reforming process have been studied working at low pressure to discriminate among the catalyst and at high pressure to prove it on industrial condition. It allows the selection of the Rh as active phase among single and bimetallic VIII group metal. The study of the matrix composition and thermal treatment has been carried out on Rh-Mg/Al hydrotalcite selected as reference catalyst. The research to optimize the catalyst lead to enhanced performances through the identification of a limitation of the Rh reduction from the oxides matrix as key point to increase the Rh performances. The Rh loading have been studied to allow the catalyst scale up for pilot process in Chieti in a shape of Rh-HT on honeycomb ceramic material. The developed catalyst has enhanced methane conversion in a inch diameter monolith reactor if compared with the semi-industrial catalyst chosen in the project as the best reference.