A novel CO2 utilization technology for the synergistic co-production of multi-walled carbon nanotubes and syngas

Dry reforming of methane (DRM) is a well-known process in which CH4 and CO2 catalytically react to produce syngas. Solid carbon is a well-known byproduct of the DRM but is undesirable as it leads to catalyst deactivation. However, converting CO2 and CH4 into solid carbon serves as a promising carbon capture and sequestration technique that has been demonstrated in this study by two patented processes. In the first process, known as CARGEN technology (CARbon GENerator), a novel concept of two reactors in series is developed that separately convert the greenhouse gases (GHGs) into multi-walled carbon nanotubes (MWCNTs) and syngas. CARGEN enables at least a 50% reduction in energy requirement with at least 65% CO2 conversion compared to the DRM process. The second process presents an alternative pathway for the regeneration/reactivation of the spent DRM/CARGEN catalyst using CO2. Provided herein is the first report on an experimental demonstration of a 'switching' technology in which CO2 is utilized in both the operation and the regeneration cycles and thus, finally contributing to the overall goal of CO2 fixation. The following studies support all the results in this work: physisorption, chemisorption, XRD, XPS, SEM, TEM, TGA, ICP, and Raman analysis.

Automated summary

This study demonstrates two patented processes for converting CO2 and CH4 into solid carbon as a potential carbon capture and sequestration technique. The first process can reduce energy requirement by at least 50% and achieve at least 65% CO2 conversion, while the second process offers an alternative pathway for the regeneration/reactivation of spent DRM/CARGEN catalyst by using CO2.