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Rational design of a methanation reactor by neutron imaging

The reaction conditions in industrial scale chemical reactors can differ markedly from the ones in a small laboratory scale reactor. The differences are both conceptual and practical, and can at best be analysed by studying a full reactor, which requires an analytical method capable of quantifying the distribution of reactants and products in a running reactor. For this, we introduce non-destructive operando neutron imaging in combination with modelling. As a representative reaction, we studied the hydrogenation of carbon dioxide to methane selected due to the large neutron cross-section of hydrogen and hydrogen-containing species. The integration of the measurement setup/reactor into the neutron beamline enables the temporally resolved measurement of the distribution of adsorbed water on the catalyst under operating conditions (p, T). The resulting quantitatively determined partial pressure of the water thus indirectly enables the spatial and temporal conversion of the processes. The knowledge gained from this experimental approach, combined with modelling, allows the design of reactor dimensions under optimized reaction conditions. The good agreement between simulation and experimental neutron imaging warrants the method as a reliable instrument for reactor characterization and design, with the prospect of its application on reactors on the industrial scale.

April 30, 2025

Low-carbon fuels (LCFs) such as green hydrogen, synthetic hydrocarbons, and biofuels are critical for decarbonizing sectors that are difficult to electrify. In this study, we present a globally harmonized techno-economic assessment of 21 LCF production pathways, including power-to-X, biomass- and sun-to-liquids, and multiple hydrogen routes, evaluated across all countries under three future scenarios for 2024, 2030, and 2050. The model integrates spatially explicit resource data, learning-driven capital cost trajectories, and dynamic, country- and technology-specific costs of capital, supported by robust scenarios and uncertainty analysis. By 2050, median levelized costs are projected to range from 0.07 to 0.10 EUR2024 per kWh for green hydrogen, 0.15 to 0.18 EUR2024 per kWh for power-to-liquid kerosene, and 0.14 to 0.20 EUR2024 per kWh for most bio-based aviation fuels, reflecting both substantial progress and persistent regional disparities. Our results show that while innovation, technology learning, and deep power sector decarbonization can unlock cost-competitive electrofuels in countries with abundant renewables, bio-based routes are frequently cost competitive for sustainable aviation fuel (SAF) production in near-term scenarios, and solar-to-liquid fuels remain constrained by feedstock availability and capital barriers. Nuclear- and methane-based hydrogen emerge as primary options in many regions, as well as the dominance of turquoise hydrogen in Russia, the Middle East, and Central Asia where carbon management is viable, which highlights the context-specific nature of future LCF systems. We also found that the least-cost logistics for global hydrogen trade will shift from ammonia shipping to pipeline transport and methanol delivery, with North Africa and Iberia emerging as leading suppliers to Europe. These findings underscore the need for integrated innovation, policy coordination, and investment strategies that address both resource and financial barriers, in order to achieve scalable, resilient, and cost-effective LCF supply chains worldwide.

Rational design of a methanation reactor by neutron imaging

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