Enhancement of Power-to-Gas via Multi-catalyst Reactors Tailoring Reaction Rate and Heat Exchange

The Sabatier reaction is a key element of power-to-gas development. For this reason, even though the process is known since more than one century, the Sabatier reaction is currently the object of important research efforts towards the development of new catalysts for performance improvement. However, the industrial exploitation of the Sabatier reaction depends on the development of reactors that match the best catalyst with an appropriate heat management. For this reason, this paper develops a methodology for the contemporary optimization of the reactor concept and the catalysts. It is observed that the reactor can be divided into three sections with contrasting requirements. In the first section, the main requirement concerns the reach of the reaction activation conditions. Hence, an adequate match between catalyst and reactor is needed, for example with an appropriate pre-heater. Once the reaction is activated, a reaction hotspot is formed, so that the cooling becomes determining and the main requirement for the catalyst is the resistance to poisoning and sintering. In the last section of the reactor, the low temperature activity of the catalyst is determining, so that a high-performing catalyst is needed. This paper indicates a strategy for the rational design of this catalyst, based on mechanistic evidences.