Integrated CO2 Capture and Utilization by Combining Calcium Looping with CH4 Reforming Processes: A Thermodynamic and Exergetic Approach Published as part of Energy & Fuels virtual special issue “Recent Advances in CO2 Conversion to Chemicals and Fuels”. Theodoros Papalas, Andy N. Antzaras,* and Angeliki A. Lemonidou Cite This: Energy Fuels 2024, 38, 11966−11979 Read Online ACCESS Metrics & More Article Recommendations *sı Supporting Information ABSTRACT: This study investigates a novel concept to coproduce high-purity H2 and syngas, which couples steam methane reforming with CaO carbonation to capture the generated CO2 and dry reforming of methane with CaCO3 calcination to directly utilize the captured CO2. The thermodynamic equilibrium of the reactive calcination stage was evaluated using Aspen Plus via a parametric analysis of various operating conditions, including the temperature, pressure, and CH4/CaCO3 molar ratio. Introducing a CH4 feed in the calcination stage promoted the driving force and completion of CaCO3 decomposition at lower temperatures (∼700 °C) compared to applying an inert flow, as a result of in situ CO2 conversion. A conceptual process design was investigated that employs a system of two moving bed reactors to produce nearly equivalent volumetric flows of pure H2 and a syngas stream with a H2/CO molar ratio close to 1. A solar reactor was examined for the reactive calcination step to cover the energy requirements of endothermic CaCO3 decomposition and dry reforming. The overall exergy efficiency of the process was found equal to ∼75.9%, a value ∼4.0 and ∼8.0% higher compared to sorption-enhanced reforming with oxy-fuel and solar calciner, respectively, without direct utilization of the captured CO2. 1. INTRODUCTION Increasing CO2 emissions derived from the excessive use of fossil fuels have triggered an immediate need for Carbon Capture, Utilization, and Storage (CCUS) technologies. Calcium looping is a promising technology for reducing the environmental footprint of the industrial sector by separating CO2 from the flue gas via the exothermic carbonation of CaO (eq 1). The carbonatedmaterial can revert back to oxide form via the reverse endothermic reaction in a separate reactor.1 Aside from postcombustion CO2 capture, calcium looping can intensify thermodynamically limited reactions, such as steam methane reforming (eq 2, SMR). Conventional SMR plants without CCUS are widely deployed at industrial scale and account for ∼50% of the worldwide production of H2, 2 a major building block for refineries and chemical and petrochemical industries and also an emerging energy carrier for transportation and electricity generation. However, SMR retains severe energy demand due to the harsh operation of the reformer (temper- atures of 800−900 °C and pressures of 20−30 bar). Another downside is the high carbon footprint due to the large quantities of CO2 emitted to the atmosphere. CO2 is a byproduct of reforming and water gas shift (eq 3, WGS) reactions and, in addition to CO2 from combusting natural gas to cover the energy demand of the reformer, ends up in the flue gas of the unit.3 Coupling calcium looping and SMR has been established as an intensified technology, called sorption-enhanced steam methane reforming (SE-SMR). The presence of CaO enables in situ capture of the byproduct CO2 and the shift of the system toward a new thermodynamic equilibrium with high H2 yield and purity in a single step while operating at lower temperatures (600−650 °C). Moreover, heat released from carbonation is exploited in situ for reforming, avoiding external fuel combustion.4,5 Received: March 27, 2024 Revised: June 7, 2024 Accepted: June 7, 2024 Published: June 21, 2024 Articlepubs.acs.org/EF © 2024 The Authors. Published by American Chemical Society 11966 https://doi.org/10.1021/acs.energyfuels.4c01462 Energy Fuels 2024, 38, 11966−11979 This article is licensed under CC-BY 4.0 https://pubs.acs.org/page/virtual-collections.html?journal=enfuem&ref=feature https://pubs.acs.org/action/doSearch?field1=Contrib&text1="Theodoros+Papalas"&field2=AllField&text2=&publication=&accessType=allContent&Earliest=&ref=pdf https://pubs.acs.org/action/doSearch?field1=Contrib&text1="Andy+N.+Antzaras"&field2=AllField&text2=&publication=&accessType=allContent&Earliest=&ref=pdf https://pubs.acs.org/action/doSearch?field1=Contrib&text1="Angeliki+A.+Lemonidou"&field2=AllField&text2=&publication=&accessType=allContent&Earliest=&ref=pdf https://pubs.acs.org/action/showCitFormats?doi=10.1021/acs.energyfuels.4c01462&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?goto=articleMetrics&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?goto=recommendations&?ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?goto=supporting-info&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=abs1&ref=pdf https://pubs.acs.org/toc/enfuem/38/13?ref=pdf https://pubs.acs.org/toc/enfuem/38/13?ref=pdf https://pubs.acs.org/toc/enfuem/38/13?ref=pdf https://pubs.acs.org/toc/enfuem/38/13?ref=pdf pubs.acs.org/EF?ref=pdf https://pubs.acs.org?ref=pdf https://pubs.acs.org?ref=pdf https://doi.org/10.1021/acs.energyfuels.4c01462?urlappend=%3Fref%3DPDF&jav=VoR&rel=cite-as https://pubs.acs.org/EF?ref=pdf https://pubs.acs.org/EF?ref=pdf https://acsopenscience.org/researchers/open-access/ https://creativecommons.org/licenses/by/4.0/ https://creativecommons.org/licenses/by/4.0/ https://creativecommons.org/licenses/by/4.0/ HCaO CO CaCO , 178 kJ/mol (s) 2(g) 3(s) 0 298 K CO2 + = (1) H CH H O 3H CO , 206 kJ/mol 4(g) 2 2(g) (g) 0 298 K CH4 + + = (2) H CO H O H CO , 41 kJ/mol (g) 2 (g) 2(g) 2(g) 0 298 K CO + + = (3) Despite the advantages of SE-SMR, the calcination is usually conducted under a pure CO2 stream in order to not dilute the CO2 released fromCaCO3 decomposition, forcing the reactor to operate at harsh temperatures (≥900 °C).6,7 The group of Farrauto has proven that using a reactive gas feed instead of CO2 in the calciner can cause the in situ conversion of captured CO2 in the presence of a suitable catalyst and drive calcination at lower temperatures, according to Le Chatelier’s principle.8,9 An example of reactive gas is CH4, which can react with the captured CO2 via dry reforming of methane (eq 4, DRM). Apart from DRM, the reverse WGS (reverse eq 3, RWGS), CH4 decomposition (eq 5), and Boudouard (eq 6) reactions may occur and affect the quality of syngas.10 H CH CO 2H 2CO , 247 kJ/mol 4(g) 2(g) 2(g) (g) 0 298 K CH4 + + = + (4) HCH C 2H , 75 kJ/mol4(g) (s) 2(g) 0 298 K CH4 + = + (5) H2CO C CO , 171 kJ/mol(g) (s) 2(g) 0 298 K CO2 + = (6) The potential of reducing the temperature of calcination has triggered the interest for various integrated CO2 capture and utilization processes,11,12 while calcium looping coupled with dry reforming of methane (CaL-DRM) has already been widely studied and applied for postcombustion CO2 capture applications.10,13−17 A major issue of this process is the carbon deposition in the reactive calcination stage.16−18 Although carbon can be gasified by CO2 in the subsequent carbonation stage, the release of CO with the CO2-stripped flue gas raises environmental concerns,13,19 while CO2 cannot completely gasify all carbon.16 Another problem is related to the partial oxidation of the Ni surface during exposure under CO2 during carbonation.15,20 Even though the formed NiO can be reduced from CH4 in the calcination stage,13 the inadequate number of Ni active sites in the beginning of the stage can affect the syngas quality. Finally, the CO2 uptake of CaO displays rapid decrease over cycles, thereby reducing the syngas production capacity.16,17 The challenges of CaL-DRM and the aforementioned high calcination temperatures of SE-SMR could be alleviated by coupling the carbonation and calcination steps of calcium looping with steam and dry-reforming of methane simulta- neously (SMR-CaL-DRM). The proposed intensified process can take place in two reactors using CH4 as carbonaceous feed to produce high-purity H2 with in situ capture of CO2 and to directly utilize the captured CO2 for syngas generation. Both H2 and syngas comprise major building blocks for the industry and the energy sector, and they can be produced from SMR and DRM in the presence of the same Ni-based catalyst. Conducting SMR along with carbonation could enable carbon deposited in the preceding calcination-DRM stage to be more efficiently gasified from H2O compared to CO2, while the produced CO could further react via theWGS reaction (eq 3) and produce H2. The presence of H2O during carbonation could also lead to higher CO2 capture activity and stability of CaO over cycles compared to operating under dry conditions, thereby securing a higher syngas uptake.7,21 Finally, the H2 generated during reforming can create a strongly reducing environment and ensure that Ni is retained in metallic form for the subsequent reactive calcination stage. The benefits of SMR-CaL-DRM dictate the necessity for further study to realize the potential of this technology. A thermodynamic analysis could indicate the optimum operating windows for the reforming and calcination stages. Despite the plethora of work on the thermodynamics of the reforming stage,22−26 studies dealing with the effect of operating conditions on calcination coupled with DRM are scarce.27,28 It is also necessary to address whether SMR-CaL-DRM can compete with SE-SMR in terms of energy efficiency, since despite the lower operating temperatures, SMR-CaL-DRM combines two highly endothermic reactions in a single stage. Conducting an exergy analysis could provide an answer to this question. Based on the second law of thermodynamics, an exergy analysis accounts for the degradation of mass and energy streams when undergoing various processes, providing a rational and meaningful assessment of the useful energy contained in a system.24,29,30 Zhang et al. reported a higher exergy efficiency for sorption-enhanced biomass gasification coupled with in situ conversion of CO2 to syngas compared to standalone sorption- enhanced gasification.28 Such a study would be fruitful for SMR- CaL-DRM, which has not yet been reported yet. The exergy analysis could also explore efficient ways to cover the energy demand of the highly endothermic calcination stage. Oxy-fuel calciners comprise the most widely studied solution for conventional calcium looping or the SE-SMR process. However, cofeeding O2 with CH4 in the calciner of SMR-CaL-DRM can decrease the selectivity toward DRM and the calcination driving force.16,31 On the other hand, solar heating comprises a sustainable approach to cover the energy demand,32,33 while solar reactors have been studied for thermochemical energy storage applications of calcium looping.34,35 In this work, Aspen Plus software is used to conduct a thermodynamic analysis of calcination coupled with DRM, along with a conceptual design and exergy analysis of the SMR- CaL-DRM process. The thermodynamic analysis aims to clarify the effect of different operating parameters, including the reactor temperature, pressure, and CH4 to CaCO3 molar ratio, on the efficiency of the reactive calcination stage. The process design is conducted by simulating both the reformer and calciner as moving bed reactors and by introducing kinetic correlations of the literature for reactions taking place. Solar heating is investigated as a means of covering the energy demand of the calcination coupled with the DRM stage, and the SMR-CaL- DRM process is evaluated from an exergetic point of view and compared to SE-SMR with either a solar or an oxy-fuel calciner. The results are expected to highlight the potential of SMR-CaL- DRM and contribute to the ongoing research on integrated CO2 capture and utilization processes. Energy & Fuels pubs.acs.org/EF Article https://doi.org/10.1021/acs.energyfuels.4c01462 Energy Fuels 2024, 38, 11966−11979 11967 pubs.acs.org/EF?ref=pdf https://doi.org/10.1021/acs.energyfuels.4c01462?urlappend=%3Fref%3DPDF&jav=VoR&rel=cite-as 2. METHODOLOGY 2.1. Thermodynamic Analysis. The effect of operating conditions on the performance of the calcination/DRM stage was evaluated via equilibrium calculations with the Aspen Plus V9 computational software. The thermophysical properties of all substances are defined by the Peng−Robinson equation of state. Equilibrium compositions are calculated using the RGIBBS model, by minimizing the Gibbs free energy of introduced components. A sensitivity analysis is performed for the calcination/DRM stage, including a range of temperatures and pressures for operating the reactor and different CH4/CaCO3 molar ratios for the inlet stream. Simulations are run by either accounting or neglecting carbon formation, while the production of compounds other than CH4, H2O, H2, CO, CO2, CaO, CaCO3, and C is considered nonthermodynamically favorable under the studied conditions. Table 1 summarizes all parameters investigated. For comparison, a simulation is run where calcination is conducted under inert flow (100 vol % N2). The above parameters are evaluated for their effect on CaCO3 and CH4 conversions, in situ CO2 utilization, purity, andH2/CO molar ratio of syngas. CaCO3 conversion is defined (eq 7) as the difference between inlet and outlet molar flows of CaCO3, divided by the inlet molar flow of CaCO3. CH4 conversion is defined similarly (eq 8) as the difference between the inlet and outlet molar flows of CH4, divided by the inlet molar flow of CH4. n n n CaCO conversion (%) 1003 CaCO CaCO CaCO 3,in 3,out 3,in = × (7) n n n CH conversion (%) 1004 CH CH CH 4,in 4,out 4,in = × (8) In situ CO2 utilization efficiency is defined (eq 9) as the CO2 moles that are converted to syngas. This is expressed as the difference between the inlet molar flow of CaCO3 and outlet molar flows of CO2 and CaCO3, divided by the inlet molar flow of CaCO3. n n n n In situ CO utilisation (%) 100 2 CaCO CaCO CO CaCO 3,in 3,out 2,out 3,in = × (9) Syngas purity is defined (eq 10) on a dry basis as the outlet molar flows of H2 and CO divided by the total molar flow in the outlet stream. TheH2/COmolar ratio is also found (eq 11) by dividing the outlet molar flows of H2 and CO. Table 1. Range of Parameters Studied for the Calcination/ DRM Stage temperature (°C) pressure (bar) CH4/CaCO3 molar ratio (−) 500−1000 1−25 0.1−3.5 Figure 1. Simulation flowchart prepared for the conceptual process design (streams colored in blue refer to inlet gas streams, red to outlet gas streams, black to other gas streams, green to utility streams, and purple to solid streams circulating between the two reactors). Energy & Fuels pubs.acs.org/EF Article https://doi.org/10.1021/acs.energyfuels.4c01462 Energy Fuels 2024, 38, 11966−11979 11968 https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig1&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig1&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig1&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig1&ref=pdf pubs.acs.org/EF?ref=pdf https://doi.org/10.1021/acs.energyfuels.4c01462?urlappend=%3Fref%3DPDF&jav=VoR&rel=cite-as n n n n n n Syngas purity (%) 100 H CO H CO CH CO 2,out ,out 2,out ,out 4,out 2,out = × + + + + (10) n n H /CO ratio ( ) 1002 H CO 2,out ,out = × (11) 2.2. Conceptual Process Design. This section describes the methodology followed for the process design and exergy analysis. Τhe main scenario studied (case 1) comprises the integrated SMR-CaL-DRM process with solar calciner and it is compared to the SE-SMR process where calcination is performed with a solar (case 2) or an oxy-fuel heating (case 3) approach. Each process is designed for a H2 production capacity of ∼11,000 N m3/h. 2.2.1. Process Flow Diagram. Figure 1 illustrates the flow diagram for the three cases, with the main difference between them being the composition of the various streams. The flow diagram consists of the following. • Steam generation and mixing with natural gas to form the gas feed of the reformer by also recycling unreacted steam condensate from the reactor outlet. • H2 production with in situ capture of CO2 in a moving bed reactor and transfer of saturated solids in a secondmoving bed reactor for CaCO3 calcination to occur. • Heat integration of the hot gas product streams for preheating the feeds of both reformer and calciner and for generating electricity in a heat recovery steam cycle. • Final compression and purification of H2 by pressure swing adsorption (PSA) and combustion of part of PSA tail gas to generate steam and preheat the feed of calciner. In the proposed conceptual design, fresh process water (stream 102) is mixed with recycled water (stream 303). The required heat for steam generation in the boiler, simulated by the array of heat exchanger B-101 and furnace F-101, is provided by combusting part of the PSA tail gas (stream 307) with air (stream 106). The generated steam is then mixed with the appropriate amount of natural gas (stream 101) to obtain a H2O to CH4 molar ratio of 3, and the total stream is finally preheated in two sequential heat exchangers (E-201 and E-202) by exploiting the heat from H2 (stream 204) generated in the reformer and gas product (stream 211) obtained from the calciner. The preheated stream (203) is then introduced in the reformer. Aspen Plus does not contain a built-in model to simulate the moving bed reactor. Therefore, the reformer is simulated with an array of three RCSTR models in series (R- 201, R-202, and R-203), which represent the top, middle, and bottom of the reactor, respectively, with this approach having been previously proposed for the simulation of moving bed reactors in Aspen Plus.36 Stream 203 enters the reformer by being introduced to RCSTR model R-201 together with a stream (213) of solid components returning from the calciner. The spent solids of the reformer (stream 214, exiting RCSTR model R-203) are then fed in the calciner, which is also simulated with an array of three RCSTR models in series (R- 204, R-205, and R-206). The solid stream is introduced to RCSTR model R-204 along with a gas inlet flow (stream 210) whose composition differentiates based on the studied case (natural gas for case 1, CO2 for case 2, and natural gas and O2 for case 3), while both gas and solid components exit the reactor from RCSTR model R-206. The gas feedstock of the calciner (stream 206) is initially preheated in an array of two heat exchangers (E-203 and E-204) using the heat of the H2 and calciner gas products (streams 205 and 212, respectively) that remains after preheating the reformer’s feed, followed by a furnace (F-201) that combusts part of the PSA tail gas (stream 308). The heat-depleted H2 product (stream 301) is further cooled using cooling water in a heat exchanger (E-301) to condense unreacted steam, which is then separated (stream 303) in a flash separation drum (D-301), in order to be recycled and reused. The gas outlet of the drum (stream 304) is compressed to 25 bar in a two-stage compressor (C-301) and the compressed gas (stream 305) is introduced to a PSA unit to remove impurities (CO2, unreacted CH4 and CO). The latter is simulated with a calculator block that defines the composition and flow of the pure H2 product (stream 306) and PSA tail gas. Most of the tail gas of the PSA unit is used as fuel for the aforementioned preheating purposes (steam generation and preheating of the calciner inlet flow), while the remaining gas is flared to the atmosphere. Regarding the gas outlet of the calciner (stream 211), after preheating the gas feed of the reformer and the calciner in heat exchangers E-202 and E-204, respectively, the temperature of the stream (313) is above 400 °C. The remaining energy is used to produce superheated steam (heat exchanger E-302), which is expanded and cooled down in a heat recovery cycle to generate electricity in steam turbine T-301. The heat-depleted stream (314) is then cooled using cooling water in heat exchanger E-304. All simulations are conducted by considering the following assumptions. • Natural gas is composed of 100 vol % CH4. • All inlet streams are delivered at 15 °C and 1 bar, while cooling water utility is available at 20 °C and 1 bar. • All heat exchangers are operated with counter-current flow of hot and cold streams, with a ΔT between the hot outlet and the cold inlet streams being 20 °C, except the preheater of the reformer (heat exchanger E-202). • The reformer operates at 1 bar and under a fully adiabatic mode. The feed of the reactor is composed of H2O and CH4 with a molar ratio of 3, while the amount of CH4 is adequate for the CH4/CaO ratio to be equal to 1. • The calciner operates at 1 bar and at 800 °C for case 1 and 900 °C for cases 2 and 3. • The above description refers to a cocurrent configuration for the moving bed reactors. Counter-current flow is also investigated by feeding streams 214 and 215 toR-203 and R-206, which results in their exit from R-201 and R-203. The reactor dimensions are the same for cocurrent and counter-current flow and are specified by accounting that in the counter-current flow, the gas velocity should be lower than the minimum fluidization velocity, calculated through the correlations of Wen and Yu.37 • The solid material circulating between the two reactors is assumed to be a bifunctional material studied in our previous work,16 with a nominal composition of 60 wt % CaO, 10 wt % NiO, and 30 wt % CaZrO3 (in reduced state). The material is assumed to have a particle size distribution between 1.8 and 3.5 mm, while similar particle sizes have been reported before in studies with moving bed reactors.38−40 Deactivation of the material over consecutive cycles is considered negligible. Energy & Fuels pubs.acs.org/EF Article https://doi.org/10.1021/acs.energyfuels.4c01462 Energy Fuels 2024, 38, 11966−11979 11969 pubs.acs.org/EF?ref=pdf https://doi.org/10.1021/acs.energyfuels.4c01462?urlappend=%3Fref%3DPDF&jav=VoR&rel=cite-as • Kinetic models from the literature are applied to describe the reactions taking place,41−45 which are presented in detail with eqs S1−S17. • The PSA unit attains 85% H2 separation with a purity of 99.999 vol %.46 • Compressors and turbines are isentropic with an efficiency of 72%. 2.2.2. Exergy Analysis. The two cases studied are further compared based on their exergetic efficiency. Standard conditions are defined as a pressure of 1 bar and temperature of 25 °C (T0). Exergy flow of a material stream j (Ėxj) consists of the chemical (Ėxchem,j), physical (Ėxphys,j), kinetic (Ėxkin,j), and potential (Ėxp,j) exergy flow terms (eq 12).29 The latter two can be neglected since neither high velocities nor large height differences are considered.47 Ex Ex Ex Ex Exj j j j p jchem, phys, kin, ,= + + + (12) The chemical and physical exergy of a stream with molar flow rate ṅj can be described by eqs 13 and 14. The standard specific exergy of each component (εi ο), needed for the calculation of the chemical exergy term, is provided in Table 2. For solids, chemical exergy is found like as they are in the gaseous phase.48 The CaZrO3 flow does not alter between the inlet and outlet streams of reactors and does not affect the analysis outcome. n x R T x xEx ln( )j j i i i i i ichem, 0 0= × × + × × × i k jjjjjj y { zzzzzz (13) n h h T s sEx ( ) ( )j j j j j jphys, 0, 0 0,= × [ × ] (14) Equations 12−14 enable the calculation of the exergy flows of inlet (Ėxin,k) and outlet (Ėxout,k) material streams for each equipment module k. Using this data, it is possible to find the exergy flow destroyed (Ėxdes,k) in module k with the equations of Table 3. Work and heat streams also affect the exergy balance of each module. Electricity needed and produced in the compressor and the turbine, respectively, can be considered equivalent to work (Ẇcomp and Ẇturb) and exergy flow. However, heat flow (Q̇s) provided by a heating source with temperature T is associated with exergy destruction (ĖxQ,calc), since not all heat can be used for work (eq 15).24,30 Q T T Ex 1Q ,calc s 0= × i k jjj y { zzz (15) Heat is required for only the solar calciners of cases 1 and 2. Calcium looping driven by concentrated solar power has been widely studied in the literature, in which a heliostat field directs solar radiation toward a tower receiver, which can be the calciner itself.48,50,51 In general, solar irradiation Q̇s depends on the surface area A of the heliostat field and on direct normal irradiance DNI, with the latter varying between geographic regions and time zones. The heat received by the tower Q̇tower is a function of Q̇s and the efficiency of the heliostat field (nhelio). Except for heliostat losses, heat lost due to radiation or reflection from the outer surface of the receiver and during the transfer of heat from the outer surface to the material within the reactor can also affect the heat exploited in the calcination/DRM stage (Q̇calc). These losses can be accounted with the efficiency of the tower receiver nrec. 51 Equation 16 shows the relation between all aforementioned terms. Q n Q n n Q n n ADNI calc rec tower rec helio s rec helio = × = × × = × × × (16) The Q̇calc term can be retrieved from the Aspen Plus simulations, while nrec and nhelio are assumed to be equal to 80 and 85%, respectively, which are average values from the literature.48,50−53 This data allows the calculation of Q̇s and ĖxQ,calc, by defining T to be equal to 5300 °C, the temperature of the outer surface of the sun.47 The heliostat field area can also be estimated by assuming an average value of 700 W/m2 for DNI.52 It should be stressed that this study focuses on the conceptual design of the process, while a more detailed design of the heliostat and the reactor would be needed for realization and accurate estimation of nrec and nhelio efficiencies, rendered out of the scope of this work. After finding the Ėxdes,k for each module k, the exergy efficiency nex can be found with eq 17. The Ėxin,tot and Ėxout,total terms refer to the total input and output exergies from material streams and they can be found from eqs 18 and 19. Streams contributing to the total input and output exergy flows are marked with blue and red color in Figure 1. n W W W W 100 Ex Ex Ex 100 Ex Ex Ex Ex Ex Q Q Q ex out,tot turb in,tot comp ,calc in,tot comp ,calc des,tot in,tot comp ,calc = × + + + = × + + + + (17) Ex Ex Ex Ex Ex Exin,tot 101 102 206 106 309= + + + + (18) Ex Ex Ex Ex Exout,tot 306 315 312 109= + + + (19) Table 2. Standard Specific Exergy for All Chemical Compounds Used (Obtained from Refs 29,49) chemical compound (−) standard specific exergy (MW/kmol) CH4 833.9 CO 277.1 CO2 19.9 H2 236.1 H2O 9.5 N2 0.72 O2 3.97 CaO 127.3 CaCO3 16.3 Table 3. Exergy Balances of Individual Modules module exergy balance heat exchangers Ėxdes,k = (Ėxin,k − Ėxout,k)hot fluid + (Ėxin,k − Ėxout,k)cold fluid furnaces Ėxdes,k = (Ėxin,k − Ėxout,k)fuel + (Ėxin,k − Ėxout,k)heated fluid compressors Ėxdes,k = Ėxin,k + Ẇcomp − Ėxout,k turbines Ėxdes,k = Ėxin,k − Ẇturb − Ėxout,k steam reformer and oxy-fuel calciner Ėxdes,k = (Ėxin,k − Ėxout,k)gas + (Ėxin,k − Ėxout,k)solid solar calciner Ėxdes,k = ĖxQ,calc + (Ėxin,k − Ėxout,k)gas + (Ėxin,k − Ėxout,k)solid mixing streams and PSA unit Ėxdes,k = Ėxin,k − Ėxout,k Energy & Fuels pubs.acs.org/EF Article https://doi.org/10.1021/acs.energyfuels.4c01462 Energy Fuels 2024, 38, 11966−11979 11970 https://pubs.acs.org/doi/suppl/10.1021/acs.energyfuels.4c01462/suppl_file/ef4c01462_si_001.pdf pubs.acs.org/EF?ref=pdf https://doi.org/10.1021/acs.energyfuels.4c01462?urlappend=%3Fref%3DPDF&jav=VoR&rel=cite-as Figure 2. Effect of temperature on (a) CaCO3 conversion when applying pure CH4 or pureN2 gas feed and (b) CH4 conversion, in situ CO2 utilization, purity, and H2/CO molar ratio of the produced syngas when applying pure CH4 gas feed (P = 1 bar, CH4/CaCO3 = 1, no carbon formation). Figure 3. Effect of pressure on (a) CaCO3 conversion, (b) CH4 conversion, (c) in situ CO2 utilization, (d) purity, and (e) H2/CO molar ratio of the produced syngas in the calcination/DRM stage (CH4/CaCO3 = 1, no carbon formation). Energy & Fuels pubs.acs.org/EF Article https://doi.org/10.1021/acs.energyfuels.4c01462 Energy Fuels 2024, 38, 11966−11979 11971 https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig2&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig2&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig2&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig2&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig3&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig3&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig3&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig3&ref=pdf pubs.acs.org/EF?ref=pdf https://doi.org/10.1021/acs.energyfuels.4c01462?urlappend=%3Fref%3DPDF&jav=VoR&rel=cite-as 3. RESULTS AND DISCUSSION 3.1. Thermodynamic Analysis. Thermodynamic calcu- lations are conducted using the RGIBBS model of Aspen Plus in order to find the optimum operating conditions for the calcination/DRM stage. The section below describes the alteration of the different performance indicators listed in eqs 7−11 as a function of the temperature, pressure, and CH4/ CaCO3 molar ratio when not accounting for carbon formation. Separate simulations are also conducted to consider carbon as the possible product. The main outcome of all simulations comprises the outlet molar flow composition of the RGIBBS model, which then allows for the calculation of the performance indicators. The outlet molar flow composition for all simulations run, along with the results of the thermodynamic analysis when accounting for carbon formation, are presented in Figures S1 and S4. Figure 2a compares the CaCO3 conversion as a function of temperature, when exposing CaCO3 under a N2 or CH4 gas flow, which reveals the clear advantage of the intensified calcination/ DRM stage. Applying the reactive CH4 flow leads to the in situ consumption of CO2 via DRM (eq 4) or RWGS (reverse eq 3) reactions. The decrease of CO2 partial pressure due to the in situ conversion and volumetric increase caused by the DRM reaction (eq 4) enhance the driving force of CaCO3 calcination, causing the system to shift toward a different thermodynamic equilibrium compared to the case where calcination is performed under an inert gas (N2) flow. Higher temperatures promote the calcination extent due to the endothermic nature of the reaction. Ultimately, full CaCO3 conversion is attained at 700 °C, a much lower temperature compared to applying the N2 gas flow. It is acknowledged that a N2 gas flow is not a realistic operation for conventional calcination compared to that using pure CO2. For the purpose of this study, N2 is used as an inert gas flow to clearly demonstrate the enhanced calcination driving force when applying a reactive CH4 gas flow. It should also be mentioned that using a pure CO2 feed would not permit conversion of CaCO3 thermodynamically until the temperature would exceed 900 °C,43 a difference of more than 200 °C compared to full CaCO3 conversion under CH4 flow. Figure 2b demonstrates the alteration of the remaining performance indicators (CH4 conversion, in situ CO2 utilization, syngas purity, and H2/CO molar ratio) as a function of temperature when applying pure CH4 flow. For temperatures up to 700 °C, where CaCO3 is incomplete and the molar ratio of CH4 to CO2 released from calcination is substoichiometric, CH4 conversion and CO2 utilization increase exponentially with temperature, with both being mainly dictated by the CO2 released from CaCO3 calcination. At temperatures above 700 °C, where full calcination is attained, CH4 conversion and CO2 utilization increase rates decline and are solely affected by the extent of the DRM and RWGS reactions at the respective temperature. It is noted that at the threshold of 700 °C, the CH4 conversion and in situ CO2 utilization exceed 70 and 80%, respectively. The purity of the generated syngas follows a trend similar to that of the other performance indicators. In the temperature range of 500−700 °C, it sharply increases from ∼5 to ∼86%, with the remaining percentage of the gas phasemainly consisting of unreacted CH4. For temperatures above 700 °C, where CaCO3 conversion is equal to 100%, the system is mainly affected by the equilibrium of DRM and RWGS. An increase in the temperature enhances the CH4 and CO2 conversions and thus the purity of the produced syngas. Finally, the H2/CO molar ratio presents an inverse volcano profile versus temper- ature, with the peak occurring at the point of complete CaCO3 calcination. As the temperature increases up to 700 °C, the ratio of CH4 to CO2 released from CaCO3 calcination remains above the stoichiometric value for DRM reaction. CO2 is the limiting reactant in this range and part of it reacted with the produced H2 via the RWGS reaction toward generating CO and H2O. The mildly endothermic RWGS seems to be favored over the strongly endothermic DRM until reaching 700 °C. Above the breakpoint of 700 °C, an increase of temperature led to the expected gradual increase of the H2/CO molar ratio close to unity, as the DRM reaction proceeded to a higher extent compared to RWGS. Overall, all reactions are interconnected with each other, and the temperature of the calcination/DRM stage can highly affect their extent and selectivity. Due to the important role of temperature in the efficiency of the calcination/DRM stage, the effect of other parameters is investigated at three different temperatures, which include the breakpoint temperature for complete calcination (700 °C), a low temperature where CaCO3 decomposition is limited (650 °C), and an elevated temperature (800 °C), where both CaCO3 and CH4 conversions are high. Figure 3 illustrates the effect of pressure on different performance indicators of the calcination/DRM stage. CaCO3 conversion presents a gradual decrease with increasing pressure at 650 and 700 °C due to the increase of partial pressure of CO2, which is the only gaseous product of the reaction. A constant full conversion precedes the aforementioned decrease for pressures up to ∼6 bar at 800 °C, which is the reason for the other performance indicators presenting two different regimes as a function of the pressure at this temperature. The first regime is related to full CaCO3 conversion and stoichiometric molar ratio of CH4 to CO2 released from calcination for pressures up to ∼6 bar, while for higher pressures, the decreasing CaCO3 conversion infers a decreasing CO2 to CH4 molar ratio as well, which affects the result. Pressure increase has a negative effect on CH4 conversion, given the volumetric increase inferred by the DRM reaction. At 800 °C, where complete calcination is attained, the negative effect of pressure on CH4 conversion is milder, since the presence of stoichiometric CO2 released from calcination promotes the extent of the reaction. After passing the threshold of ∼6 bar, the CH4 conversion is affected by both the negative effect of pressure on the DRM reaction and the decreasing CO2 content, thereby leading to a more pronounced effect of pressure, similar to 650 and 700 °C. The in situ CO2 utilization and syngas purity follow the same trend as CH4 conversion with increasing pressure, with unreacted CH4 being the main impurity in the syngas. Lastly, the pressure increase has a different effect on the H2/ COmolar ratio for the various temperatures studied, depending on the extent of CaCO3 conversion. At 650 and 700 °C, where CaCO3 calcination and therefore release of CO2 are largely suppressed with increasing pressure, the H2/CO ratio is relatively stable. The lower H2/CO molar ratio at 700 °C compared to 650 °C could be attributed to the extent of RWGS, which, in contrast to DRM is only affected by temperature and not pressure changes, as it is equimolar on reactants and products. However, as both DRM and calcination reactions are negatively affected by the pressure increase, the lower amounts of H2 and CO2 shift the RWGS equilibrium toward the reactants side, leading to an increasing H2/COmolar ratio as a function of Energy & Fuels pubs.acs.org/EF Article https://doi.org/10.1021/acs.energyfuels.4c01462 Energy Fuels 2024, 38, 11966−11979 11972 https://pubs.acs.org/doi/suppl/10.1021/acs.energyfuels.4c01462/suppl_file/ef4c01462_si_001.pdf https://pubs.acs.org/doi/suppl/10.1021/acs.energyfuels.4c01462/suppl_file/ef4c01462_si_001.pdf pubs.acs.org/EF?ref=pdf https://doi.org/10.1021/acs.energyfuels.4c01462?urlappend=%3Fref%3DPDF&jav=VoR&rel=cite-as pressure. At 800 °C and pressures up to ∼6 bar (complete CaCO3 calcination), the H2/CO molar ratio decreases due to the high partial pressure of CO2, which shifts the RWGS toward the side of the products, while DRM is inhibited by the pressure increase. When pressures reach above ∼6 bar at 800 °C, the H2/ CO molar ratio increases due to the indirect influence of the DRM and calcination extents on RWGS. As CH4 is the only reactant in the gas feed of the calcination/ DRM stage, variation of the CH4/CaCO3 molar ratio can considerably affect the efficiency of the stage (Figure 4). The increase in the CH4 feed enhances the in situ CO2 consumption and CaCO3 conversion, with more CO2 needing to be released to reach the equilibrium partial pressure. Higher temperatures require lower CH4/CaCO3 molar ratios for full CaCO3 conversion, since calcination can proceed under a higher CO2 partial pressure in the gas phase. On the other hand, CH4 conversion is initially stable as a function of the CH4/CaCO3 molar ratio when operating at either 650 or 700 °C, indicating that the increase of the CH4 flow causes the release of an adequate amount of CO2 from CaCO3 decomposition to retain stable CH4 conversion. Upon reaching full CaCO3 conversion, the molar ratio of CH4 to CO2 released from calcination is above the stoichiometric one, leading to a gradual decrease of CH4 conversion from this point onward. At 800 °C, CH4 conversion remains at values higher than 94% for substoichiometric molar ratios (CH4/CaCO3 < 1) due to the high reaction temperature and availability of CO2, which both promote the DRM. The in situ CO2 utilization displays an increasing trend as a function of CH4/CaCO3 molar ratio, similar to CaCO3 conversion, at 650 or 700 °C. The increase of CO2 utilization and the stable CH4 conversion until reaching full CaCO3 conversion prove that CO2 is the limiting agent that controls the equilibrium, resulting in the production of syngas with stable purity and H2/CO molar ratio close to unity. After reaching full Figure 4. Effect of CH4/CaCO3 molar ratio on (a) CaCO3 conversion, (b) CH4 conversion, (c) in situ CO2 utilization, (d) purity, and (e) H2/CO molar ratio of the produced syngas in the calcination/DRM stage (P = 1 bar, no carbon formation). Energy & Fuels pubs.acs.org/EF Article https://doi.org/10.1021/acs.energyfuels.4c01462 Energy Fuels 2024, 38, 11966−11979 11973 https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig4&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig4&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig4&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig4&ref=pdf pubs.acs.org/EF?ref=pdf https://doi.org/10.1021/acs.energyfuels.4c01462?urlappend=%3Fref%3DPDF&jav=VoR&rel=cite-as CaCO3 conversion, the CO2 utilization continues to slightly increase, since the excess CH4 enhances the extent and selectivity of DRM compared to RWGS, as also indicated by the increase of the H2/CO molar ratio. However, excess CH4 decreases the purity of the syngas. At 800 °C and CH4/CaCO3 molar ratios lower than unity, CO2 utilization and syngas purity are dictated by the enhancement of DRM and RWGS with higher CH4 contents, resulting in a different increasing trend compared to 650 and 700 °C, where the CaCO3 conversion extent also affects the CO2 utilization. The H2/CO molar ratio of syngas is lower at these conditions due to the presence of unconverted CO2. Overall, the results of the thermodynamic analysis provide the operating conditions for successfully integrating CaCO3 calcination and DRM reactions in a single step. Full CaCO3 conversion requires a minimum temperature of ∼700 °C for CH4/CaCO3 = 1 while attaining an in situ CO2 utilization of ∼80% toward the production of syngas with H2/COmolar ratio close to unity. Pressure increase results in lower conversions as neither CaCO3 calcination nor DRM are favored, indicating that pressures close to atmospheric are the optimum operating conditions for this integrated process. The CH4/CaCO3 molar ratio should be appropriately adjusted for the molar ratio of inlet CH4 to released CO2 to be close to unity. The aforementioned results are obtained without accounting carbon as a possible product of the thermodynamic analysis. As mentioned before, separate simulations are run where carbon formation is considered, with results being presented in Figures S1 and S2. Carbon formation is promoted at low temperatures (660−680 °C) from a thermodynamics point of view, which highlights the necessity for appropriate catalysts that can kinetically suppress the extent of carbon formation in a potential demonstration of the process. Given the potential to suppress carbon formation in a real-life application of the SMR-CaL-DRM process by operating the calcination/DRM stage at high temperatures and by using appropriate catalysts, carbon generation is not further studied in this work and the subsequent process design. 3.2. Process Design. Aspen Plus is then applied to propose a conceptual design for the SMR-CaL-DRM process. A comprehensive analysis is provided for the results from the design of case 1 of interest, where the reforming and calcination/ DRM stages are conducted in a system of two moving bed reactors. The integrated process is then compared to the SE- SMR in terms of exergy efficiency. The conditions of each stream of the flow diagram of SMR-CaL-DRM (case 1) and SE- SMR with a solar (case 2) or an oxy-fuel calciner (case 3) are presented in Tables S4−S6. 3.2.1. Performance of SMR-CaL-DRM in a System of Two Moving Bed Reactors. Setting ∼11,000 Nm3/h of H2 as a desirable production target and a H2O/CH4 molar flow ratio of 3 for operating the reformer can define the inlet volumetric flow of the reactor. The diameter is chosen to be equal to ∼1.46 m to avoid fluidization of the solid particles when designing the reactor as a moving bed with counter-current flow of gas and solids. Based on the applied kinetic correlations, the reactor has a total volume of∼7.5 m3 (height of∼4.4 m) to attain at least 90% CH4 conversion. The reformer operates adiabatically, with the inlet gas feedstock preheated at 630 °C and the solid components circulating back from the calciner at 800 °C. Figure 5 presents the temperature, CH4 conversion, H2 purity, and CaO conversion profiles in the axial direction of the reformer with a cocurrent flow of gas and solid components. The aforemen- tioned performance indicators are calculated based on eqs S18 and S20. In the cocurrent flow (Figure 5a), where both gases and solids enter from the top of the reactor and move downward, CH4 conversion and CO2 capture occur simultaneously, since the inlet CH4 comes in contact with CaO from the calciner. CO2 capture boosts the driving force of WGS and SMR, thereby leading to ∼80% CH4 conversion and ∼90% purity of the generated H2 at the exit of the first RCSTR model. Conversions of CH4 and CaO continue as the gas and solid compounds transcend the reactor, while at the bottom, ∼90% CH4 has been consumed to produce H2 with ∼95% purity. Throughout the reactor length, temperature ranges between 570 °C at the upper part of the reactor, where the endothermic reforming occurs to a higher extent, and 600 °C at the bottom. When simulating the reformer as a moving bed with counter- current flow (Figure 5b), solid compounds perform a downward flow within the reactor and meet the gaseous components that Figure 5. CH4 conversion, H2 purity, CO2 capture, and temperature profiles in the axial direction of the reformer moving bed reactor with (a) cocurrent and (b) counter-current flow of gas and solid compounds (P = 1 bar, H2O/CH4 = 3, CH4/CaO = 1). Schematics on top of the figures display the part of the reactor that each unit represents. Energy & Fuels pubs.acs.org/EF Article https://doi.org/10.1021/acs.energyfuels.4c01462 Energy Fuels 2024, 38, 11966−11979 11974 https://pubs.acs.org/doi/suppl/10.1021/acs.energyfuels.4c01462/suppl_file/ef4c01462_si_001.pdf https://pubs.acs.org/doi/suppl/10.1021/acs.energyfuels.4c01462/suppl_file/ef4c01462_si_001.pdf https://pubs.acs.org/doi/suppl/10.1021/acs.energyfuels.4c01462/suppl_file/ef4c01462_si_001.pdf https://pubs.acs.org/doi/suppl/10.1021/acs.energyfuels.4c01462/suppl_file/ef4c01462_si_001.pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig5&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig5&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig5&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig5&ref=pdf pubs.acs.org/EF?ref=pdf https://doi.org/10.1021/acs.energyfuels.4c01462?urlappend=%3Fref%3DPDF&jav=VoR&rel=cite-as move upward. Even though the final CH4 conversion, H2 purity, and CaO conversion are similar to the ones attained with cocurrent flow, the axial temperature profile inside the reactor is broader. Gaseous CH4 enters from the bottom and comes in contact with descending solids, which, however, under steady- state conditions, are already in a partially carbonated form. Therefore, SMR occurs without its heat demand being completely covered from CaO carbonation, leading to the decrease of temperature at ∼510 °C. Furthermore, SMR is not intensified to a high extent, leading to lower CH4 conversion and H2 purity compared to the cocurrent flow. As the gaseous compounds reach higher heights, they come in contact with more unreacted CaO. Since the extent of CaO carbonation is higher than SMR at the upper parts of the reactor, this leads to a temperature increase up to ∼630 °C. The cocurrent flow of gas and solid components leads to a more uniform temperature profile, with 30 °C difference between the top and the bottom of the reactor and both the gaseous and solid compounds being retrieved at ∼600 °C. The cocurrent flow also attains an optimum coupling of SMR and CaO carbonation. On the other hand, the counter-current flow moving bed reactor results in a temperature difference of ∼120 °C between the top and the bottom of the reactor, the exit of the gaseous and solid compounds at different temperatures (∼510 and ∼630 °C, respectively), and the nonefficient coupling of SMR and CaO carbonation. The low temperature of solids and the higher difference compared to the operating temperature of the calcination/DRM stage (800 °C) would result in an undesirable higher energy demand for the latter. Due the aforementioned statements, the moving bed reactor with cocurrent flow of gaseous and solid compounds is deemed a more appropriate configuration for the reformer reactor. The reformate gas undergoes cooling, while after purification, a stream with ∼11,010 N m3/h flow and 99.999 vol % H2 composition is retrieved, reaching the production target. Solid materials that exit the reformer comprise Ni, CaCO3, CaZrO3, and unreacted CaO and enter the calciner with a stream of pure CH4. The reactor is designed with a diameter of Table 4. Main Exergy Results for the SMR-CaL-DRM and SE-SMR Processes exergy term SMR-CaL-DRM with solar calciner (case 1) SE-SMR with solar calciner (case 2) SE-SMR with oxy-fuel calciner (case 3) Ẇturb (MW) 0.18 0.19 0.16 Ẇcomp (MW) 2.18 2.18 2.18 ĖQ,calc (MW) 22.69 11.20 0 Ėxin,tot (MW) 64.57 35.71 43.21 Ėxout,tot (MW) 67.70 33.10 32.56 nexergy (%) 75.92 67.81 72.10 Ėxdes,tot 81.06 (MJ/kmol H2 + syngas) 124.10 (MJ/kmol H2) 99.47 (MJ/kmol H2) Figure 6.Distribution of exergy destroyed in (a) SMR-CaL-DRM process with a solar calciner and the SE-SMR process with (b) solar or (c) oxy-fuel calciner. Energy & Fuels pubs.acs.org/EF Article https://doi.org/10.1021/acs.energyfuels.4c01462 Energy Fuels 2024, 38, 11966−11979 11975 https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig6&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig6&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig6&ref=pdf https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462?fig=fig6&ref=pdf pubs.acs.org/EF?ref=pdf https://doi.org/10.1021/acs.energyfuels.4c01462?urlappend=%3Fref%3DPDF&jav=VoR&rel=cite-as ∼1.65 m and a length of ∼4.18 m and operates isothermally at 800 °C and a cocurrent flow of gas and solid components. Counter-current flow is not simulated for the calciner, since the introduction of CH4 from the bottom would result in its contact with already partially calcined material, and the substoichio- metric molar ratio of CO2 released from calcination to CH4 would promote carbon formation. The operating temperature is chosen based on the results of the thermodynamic analysis to allow high CH4 and CO2 conversion toward syngas generation (Figure 2). Cocurrent flow of solids and gas components enables to attain 97% CH4 conversion toward syngas production with ∼12,130 N m3/h volumetric flow and H2/CO molar ratio close to unity. The CaCO3 reaches full decomposition at the bottom of the reactor, attaining an in situ CO2 utilization of 98%. To perform the two endothermic reactions, a total of ∼16.3 MW or ∼116MJ per kmol of syngas produced is required for isothermal operation at 800 °C, which would require a heliostat field of approximately 0.04 km2. The area of the heliostat field could be specified accurately depending on the geographic region of the unit and the DNI value. 3.2.2. Exergy Analysis Results. The main inlet and outlet flows considered in the exergetic analysis for the material streams, work of compressors and turbines, and energy required in the calciner are presented in Table 4 and compared between the three cases. The SMR-CaL-DRM unit (case 1) is characterized by a higher inlet exergy flow for the material streams (Ėxin,tot), since more CH4 is required in the integrated reactive calciner compared to the amount of CH4 needed for the oxy-fuel calciner of case 3, while no CH4 is required for the solar calciner of case 2. Moreover, the aforementioned requirement for 16.30 MW of energy for operating the endothermic calcination/DRM stage (Q̇calc) corresponds to the required solar irradiation (Q̇s) of 23.97 MW and an inlet exergy flow of 22.69 MW (ĖxQ,calc) for case 1. The inlet exergy flow for solar radiation is lower for case 2 since only the calcination reaction occurs in the reactor, while no exergy flow of heat is required for the autothermal oxy-fuel calciner (case 3). Despite the much higher total inlet exergy flow for case 1, the retrieval of two high- value products (high-purity H2 and syngas) results in much higher outlet exergy flow from material streams (Ėxout,tot) compared to both case 2 and case 3 and a slightly higher (by 8 and 4%) overall exergy efficiency of the whole process (75.92% instead of 67.81 and 72.10%). Furthermore, the total exergy destroyed in case 1 is equal to 81.06 MJ/kmol of high-value products, which is ∼22.7 and ∼18.5% lower compared to the respective exergy destruction in case 2 and case 3. Figure 6 breaks down the contribution of different modules in the exergy destroyed in each case. The dominant section contributing to the exergy destruction for case 1 is the solar calciner (≥55%) as a result of heat needed to drive the two endothermic reactions. This is followed by the heat exchangers (≥25%) and more specifically the boiler needed to generate the steam for the reformer (simulated by heat exchanger B-101 coupled with furnace F-101). The remaining exergy destruction (∼20%) is attributed to the reformer, the operation of the compressor and turbine units, the mixing of CH4 and H2O streams for the reformer, and the nonexploited content of the flare gas. In case 2, the solar calciner has a lower contribution to the total exergy destroyed since there is no significant chemical exergy change between the inlet and outlet streams, while the energy needed is much lower compared to the calciner of case 1. In case 3, heat exchangers are considered the main source of exergy destruction (∼50%), followed by the calciner whose exergy destruction is a result of the conversion of a stream with high chemical exergy (mixture of CH4 and O2) to a stream with low chemical exergy (mixture of CO2 and H2O). The lower contribution of the oxy-fuel calciner to the exergy destroyed compared to case 1 and case 2 signifies that future research could be focused on improving the efficiency of solar calcination and on a more detailed design of such reactors. Nonetheless, despite solar calciners being currently less promising compared to oxy- fuel calciners, the slightly higher exergy efficiency of SMR-CaL- DRM (case 1) indicates that even though two highly endothermic reactions are coupled in a single step, reactive calcination with solar heating can present a more attractive option. 4. CONCLUSIONS Coupling steam methane reforming with calcium looping can lead to in situ removal of generated CO2 and elevated CH4 conversion toward high-purity H2 production in a single step. Commercializing the sorption-enhanced reforming technology relies on finding efficient methods to moderate the elevated temperatures of calcination. This work investigated an intensified process that integrates a reactive calciner in sorption-enhanced reforming to in situ utilize the captured CO2, by coupling calcination with dry reforming of methane. With both reformer and calciner being fed with CH4, this process coproduces high-purity H2 and syngas. The concept was evaluated from a thermodynamics point of view, focusing on the operation of the calcination stage, followed by a preliminary design of the integrated process while employing a system of two moving bed reactors. Solar heating was evaluated as a means of covering the energy demand of the calciner by conducting an exergy analysis to compare the proposed integrated process with a sorption-enhanced steam methane reforming process with either a solar or an oxy-fuel calciner. The main outcomes of this work are presented below. • The complete decomposition of CaCO3, along with ∼80% in situ utilization of CO2 toward syngas generation were feasible thermodynamically at 700 °C, a milder temperature than conventional calcination (800−900 °C). The lower operating temperature proved that the reactive gas feed enhances the driving force of calcination. • Cocurrent flow of gases and solids in a reformer with a moving bed configuration enabled for the adiabatic production of ∼11,000 N m3/h H2 at 600 °C, while an isothermal operation of the calciner at 800 °C resulted in the generation of similar amount of syngas (∼12,130 Nm3/h) with H2/COmolar ratio close to unity. Counter- current flow was related to a more expanded profile of temperature in the axial direction of the reformer. • Solar calcination was linked with higher exergy destruction compared to an oxy-fuel calciner. However, the in situ conversion of CO2 toward syngas allowed for the integrated proposed process to display an efficiency of ∼75.9%, a value ∼8 and ∼4% higher compared to the benchmark process with the solar and oxy-fuel calciner. The results of this work highlighted the potential of the proposed process and intensified the interest for its experimental demonstration in the future. Energy & Fuels pubs.acs.org/EF Article https://doi.org/10.1021/acs.energyfuels.4c01462 Energy Fuels 2024, 38, 11966−11979 11976 pubs.acs.org/EF?ref=pdf https://doi.org/10.1021/acs.energyfuels.4c01462?urlappend=%3Fref%3DPDF&jav=VoR&rel=cite-as ■ ASSOCIATED CONTENT *sı Supporting Information The Supporting Information is available free of charge at https://pubs.acs.org/doi/10.1021/acs.energyfuels.4c01462. Kinetic rate equations used for process design simu- lations, results of thermodynamic analysis when account- ing carbon formation, molar flow composition of the outlet of the calcination/DRM stage as a function of the temperature, pressure, and CH4/CaCO3 (PDF) ■ AUTHOR INFORMATION Corresponding Author Andy N. Antzaras − Department of Chemical Engineering, Aristotle University of Thessaloniki, 54124 Thessaloniki, Greece; orcid.org/0000-0002-7896-1392; Email: aantzara@cheng.auth.gr Authors Theodoros Papalas − Department of Chemical Engineering, Aristotle University of Thessaloniki, 54124 Thessaloniki, Greece; Department of Chemical Engineering and Biotechnology, University of Cambridge, CB3 0AS Cambridge, U.K.; orcid.org/0000-0002-5122-5125 Angeliki A. Lemonidou − Department of Chemical Engineering, Aristotle University of Thessaloniki, 54124 Thessaloniki, Greece; Chemical Process & Energy Resource Institute, CPERI/CERTH, Thessaloniki 57001, Greece; orcid.org/0000-0001-8376-0678 Complete contact information is available at: https://pubs.acs.org/10.1021/acs.energyfuels.4c01462 Funding The open access publishing of this article is financially supported by HEAL-Link. Notes The authors declare no competing financial interest. ■ ACKNOWLEDGMENTS The research project was supported by the Hellenic Foundation for Research and Innovation (H.F.R.I.) under the “3rd Call for H.F.R.I. Research Projects to support Post-Doctoral Research- ers” (Project Number 7155). Dr. Theodoros Papalas acknowl- edges the State Scholarship Foundation for the support of his Ph.D. Thesis, which was cofinanced by Greece and the European Union (European Social Fund�ESF) through the Operational Program “Human Resources Development, Edu- cation and Lifelong Learning” in the context of the Act “Enhancing Human Resources Research Potential by under- taking a Doctoral Research”, Subaction 2: IKY Scholarship Programme for Ph.D. candidates in Greek Universities. The authors thank Dr. Athanasios Skaltsogiannis for the fruitful discussions for the kinetic rate equations. Finally, the authors acknowledge the contribution of Mr. Ioannis Kazantzidis in the conduction of the simulations of this work. ■ NOMENCLATURE A area of heliostat field DNI direct normal irradiance Ėxdes,k exergy flow destroyed in module k Ėxdes,tot total exergy flow destroyed from modules and flare gas Ėxj exergy flow of stream j Ėxchem,j chemical exergy flow of stream j Ėxin,k total exergy flow of inlet material streams of module k Ėxin,tot total input exergy flow in the case studied Ėxkin,j kinetic exergy flow of stream j Ėxout,k total exergy flow of outlet streams of module k Ėxout,tot total output exergy flow in the case studied Ėxp,j potential exergy flow of stream j ĖxQ,calc exergy flow of heat required in the calciner Ėxphys,j physical exergy flow of stream j hj enthalpy of stream j h0,j enthalpy of stream j at standard conditions nex exergy efficiency of the studied case nhelio efficiency of heliostat field ṅj molar flow of stream j ṅi,in inlet molar flow of component i ṅi,out outlet molar flow of component i nrec efficiency of heat transfer in the calciner Q̇calc heat flow required for reactions occurring inside the calciner Q̇s heat flow provided by a heating source Q̇tower heat flow reaching the outer surface of the calciner receiver P pressure R ideal gas constant sj entropy of stream j s0,j entropy of stream j at standard conditions T temperature T0 temperature at standard conditions Ẇcomp work of compressor Ẇturb work of turbine xi molar fraction of component i εi 0 standard specific exergy of component i ■ ABBREVIATIONS CCUS carbon capture utilization and storage CaL-DRM calcium looping coupled with dry reforming of methane DRM dry reforming of methane PSA pressure swing adsorption RWGS reverse water gas shift SE-SMR sorption-enhanced steam methane reforming SMR steam methane reforming SMR-CaL-DRM steam methane reforming coupled with calcium looping and dry reforming of methane WGS water gas shift ■ REFERENCES (1) Garcia, J. 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