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6.5 The Sabatier Reactor: Overview and Optimization Considerations 47 aqueous PEC TRL is quite low, and it may be more expedient to rely on higher TRL technologies to produce O2 and CH4. One such route is the electrolysis of water to H2 and O2 (a TRL 9 technology), followed by a Sabatier reaction of H2 and CO2. The Sabatier reaction is a reversible, highly exothermic, and highly stable reaction for >95% methane production under selective catalyst and thermal conditions. Lower operating temperatures favor high conversion to CH4 and H2O, and the reaction is typically favorable at approximately 400◦C. The Sabatier reaction is expressed in Equation 6.1. k+1 CO2 + 4 H2 −−−→ CH4 + 2 H2O (6.1) The methanation reaction via Sabatier has been investigated using various catalysts, including nickel (Dew et al., 1955), Ruthenium on alumina (Lunde & Kester, 1973; Muscatello et al., 2016; Brooks et al., 2007), and Ruthenium on mixed phase TiO2. A Sabatier assembly exists on the International Space Station (ISS) (Samplatsky et al., 2011) for life-support systems, utilizing the CO2 from waste cabin air. Sabatier systems are also being developed for deep space human missions to Mars as in-situ resource utilization (ISRU) applications (Muscatello et al., 2016; Junaedi et al., 2014; Junaedi et al., 2011). 6.5.2 Sabatier Reactor Design Considerations Different reactor designs have been proposed to increase the operating space velocities, long duration operation, and minimal mass. In particular, researchers have investigated microlith substrates (Junaedi et al., 2014; Junaedi et al., 2011), microchannel (Brooks et al., 2007; Thompson, 2015), and packed bed reactors (Muscatello et al., 2016; Samplatsky et al., 2011) to optimize catalyst surface area, space velocity, high CO2 conversion with high CH4 selectivity, and thermodynamic controls. The mass, power, and operating ranges of these systems all vary widely in terms of the gas hourly space velocity (GHSV), temperature range, feed molar ratio, feed flow rate, and pressure, as displayed in Table 6.4. The traditional packed bed Sabatier reactor is limited by the operational space velocities. The two reported microchannel reactors have varying GHSVs, while the microlith reactor has the highest performance for GHSV. Alternative reactor design can offer us ways of operating the Sabatier reactor at higher space velocities. The microlith (Junaedi et al., 2014; Junaedi et al., 2011) and microchannel (Junaedi et al., 2011) style reactors offer higher GHSVs than the traditional packed bed reactor, while not compromising the conversion rates. Increasing the operating space velocities means that the reactor does not need to be as large, which can translate to mass reduction. Stoichiometric feed conditions of the H2:CO2 ratio are due to applications. A life support application on ISS or in human presence with safety considerations runs CO2 rich at sub EarthPDF Image | ISRU Challenge Production of O2 and Fuel from CO2
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