Development of OTM Syngas Process and Testing of Syngas Derived Ultra-clean Fuels in Diesel Engines and Fuel Cells

Abstract

This final report summarizes work accomplished in the Program from January 1, 2001 through December 31, 2004 Most of the key technical objectives for this program were achieved. A breakthrough material system has lead to the development of an OTM (oxygen transport membrane) compact planar reactor design capable of producing either syngas or hydrogen. The planar reactor shows significant advantages in thermal efficiency and a step change reduction in costs compared to either autothermal reforming or steam methane reforming with CO 2 recovery.Syngas derived ulltra-clean transportation fuels were tested in the Nuvera fuel cell modular pressurized reactor and in International Truck and Engine single cylinder test engines. The studies compared emission and engine performance of conventional base fuels to various formulations of ultra-clean gasoline or diesel fuels. A proprietary BP oxygenate showed significant advantage in both applications for reducing emissions with minimal impact on performance. In addition, a study to evaluate new fuel formulations for an HCCI engine was completed. List of Tables Page Executive SummaryContinued concerns about environmental quality are driving the need for development of ultra-clean transportation fuels (UCTF) and low emission vehicle propulsion systems. Natural gas is an attractive feed for the production of UCTF because it can be converted into an array of sulphur free fuels including synthetic gasoline, synthetic diesel, methanol, and other oxygenates. These fuels, when used neat or blended with conventional petroleum products have the potential to dramatically reduce emissions while providing an alternative (non-petroleum) energy source.The processes for producing UCTF all utilize a common first step whereby natural gas is converted to syngas, a mixture of hydrogen, carbon monoxide, carbon dioxide and water. The syngas can be converted to synthetic gasoline and diesel via the Fischer Tropsch process or to methanol or other oxygenates by proprietary technologies. In all cases, over 50% of the capital cost and a significant fraction of the operating costs are associated with syngas production.This program had two primary objectives: 1) develop an advanced, syngas technology based on ceramic oxygen transport membranes that will provide a step change reduction in the conversion costs of natural gas to syngas and 2) evaluation of syngas derived ultra-clean fuels in fuel cells; and the development of advanced compression ignition engines/after treatment /ultra-clean fuel systems. The first objective was expanded in Budget Period 3 to include OTM based hydrogen production, which is another type of UCTF. The second objective was modified in Budget Period 2 to include preliminary development work on a HCCI (homogenous charged compression ignition) engine. Some envisage the HCCI as the next generation internal combustion engine to replace conventional diesel engines.The OTM Alliance team assembled to address these issues includes fuel producers, an industrial gas supplier a...