Biomass gasification is one of the most promising routes to produce green hydrogen, power, fuels, and chemicals, which has drawn much attention as the world moves away from fossil fuels. Syngas produced from gasification needs to go through an essential gas cleanup step for the removal of tars and particulates for further processing, which is one of the cost-inducing steps. Existing hot gas cleanup strategies involve the particulate removal step followed by catalytic tar reforming, which could be integrated into a single unit operation using porous ceramics owing to their advantages including high-temperature resistance, high corrosion resistance, flexibility, and robust mechanical integrity. Ceramic filters have proven to be effective at filtering particulates from hot gas streams in various applications including combustion, incineration, gasification, and pyrolysis. These materials have also been evaluated and used to an extent as catalyst support to remove contaminants such as nitrogen oxides (NO_x), volatile organic compounds (VOC), and in particular, tars, however, the use of these ceramic materials to remove both tars and particulates in one unit has not received much attention, although it has a promising potential to be a cost-effective hot gas cleanup strategy. Thus, this review presents the ability of catalytic ceramic filters to boost energy efficiency by converting unwanted byproducts while simultaneously eliminating PM in a single unit and is shown to be valuable in industrial processes across the board. This article presents a comprehensive and systematic overview and current state of knowledge of the use of porous ceramics for catalytic hot gas filtration applications with an emphasis on biomass syngas cleanup. In addition, a similar strategy for other applications such as combustion exhaust streams is presented. Prospects and challenges of taking this approach, and the necessary research and development to advance the novel use of reactive ceramic filters within biomass-fed thermal systems are presented. Major challenges include the low surface area of the ceramic filter media and high-pressure drop across the filter media, which can be overcome by wash coating or dip coating mechanisms and porosity tailored to meet the requirements. Owing to limited R&D efforts in this area, a systematic approach toward developing these integrated hot gas filtration systems is much needed, which will ultimately contribute to cost-effective green hydrogen production.

Biomass is an excellent sustainable carbon neutral energy source, however its use as a coal/petroleum coke substitute in thermal applications poses several challenges. Several inherent properties of biomass including higher heating value (HHV), bulk density, and its hydrophilic and fibrous nature, all contribute to challenges for it to be used as a solid fuel. Torrefaction or mild pyrolysis is a well-accepted thermal pretreatment technology that solves most of the above-mentioned challenges and results in a product with superior coal-like properties. Torrefaction involves the heating of biomass to moderate temperatures typically between 200 °C and 300 °C in a non-oxidizing atmosphere. This study focused on evaluating the influence of torrefaction operating temperature (204–304 °C) and residence time (10–40 min) on properties of pine. Tests were performed on a continuous 0.3 ton/day indirectly heated rotary reactor. The influence of torrefaction operational conditions on pine was evaluated in terms of the composition of torrefied solids, mass yield, energy yield, and HHV using a simulated model developed in Aspen Plus™ software. A kinetic model was established based on the experimental data generated. An increase in torrefaction severity (increasing temperature and residence time) resulted in an increase in carbon content, accompanied with a decrease in oxygen and hydrogen. Results from the simulated model suggest that the solid and energy yields decreased with an increase in temperature and residence time. Solid yield varied from 80% at 204 °C to 68% at 304 °C, and energy yield varied from 99% at 204 °C to 70% at 304 °C, respectively. On the other hand, HHV improved from 22.8 to 25.1 MJ/kg with an increase in temperature at 20 min residence time. Over the range of 10 to 40 min residence time at 260 °C, solid and energy yields varied from 77% to 59% and 79% to 63%, respectively; however the HHV increased by only 3%. Solid yield, energy yield, and HHV simulated data were within the 5% error margin when compared to the experimental data. Validation of the simulation parameters was achieved by the conformance of the experimental and simulation data obtained under the same testing conditions. These simulated parameters can be utilized to study other operating conditions fundamental for the commercialization of these processes. Desirable torrefaction temperature to achieve the highest solid fuel yield can be determined using the energy yield and mass loss data.

Amongst the issues associated with the commercialization of biomass gasification, the presence of tars has been one of the most difficult aspects to address. Tars are an impurity generated from the gasifier and upon their condensation cause problems in downstream equipment including plugging, blockages, corrosion, and major catalyst deactivation. These problems lead to losses of efficiency as well as potential maintenance issues resulting from damaged processing units. Therefore, the removal of tars is necessary in order for the effective operation of a biomass gasification facility for the production of high-value fuel gas. The catalytic activity of montmorillonite and montmorillonite-supported nickel as tar removal catalysts will be investigated in this study. Ni-montmorillonite catalyst was prepared, characterized, and tested in a laboratory-scale reactor for its efficiency in reforming tars using naphthalene as a tar model compound. Efficacy of montmorillonite-supported nickel catalyst was tested as a function of nickel content, reaction temperature, steam-to-carbon ratio, and naphthalene loading. The results demonstrate that montmorillonite is catalytically active in removing naphthalene. Ni-montmorillonite had high activity towards naphthalene removal via steam reforming, with removal efficiencies greater than 99%. The activation energy was calculated for Ni-montmorillonite assuming first-order kinetics and was found to be 84.5 kJ/mole in accordance with the literature. Long-term activity tests were also conducted and showed that the catalyst was active with naphthalene removal efficiencies greater than 95% maintained over a 97-h test period. A little loss of activity was observed with a removal decrease from 97% to 95%. To investigate the decrease in catalytic activity, characterization of fresh and used catalyst samples was performed using thermogravimetric analysis, transmission electron microscopy, X-ray diffraction, and surface area analysis. The loss in activity was attributed to a decrease in catalyst surface area caused by nickel sintering and coke formation.

Methyl mercaptan is a sulfur-based chemical found as a co-product in produced natural gas and it causes corrosion in pipelines, storage tanks, catalysts, and solid adsorption beds. To improve the quality of methane produced, researchers have studied the use of metal oxides and aluminum silicates as catalysts for removing mercaptan. However, there are restrictive limitations on the efficiency of metal oxides or aluminum silicates as adsorbents for this application. Therefore, this study investigated the performance of these materials in a fixed-bed reactor with simulated natural gas streams under various operating conditions. The testing procedure includes a detailed assessment of the adsorbent/catalysts by several techniques, such as Braeuer–Emmett–Teller (BET), Scanning Electron Microscope (SEM), Energy-Dispersive X-ray Spectrometry (EDS), and X-ray Photoelectron Spectroscopy. The results revealed that metal oxides such as copper, manganese, and zinc performed well in methyl mercaptan elimination. The addition of manganese, copper, and zinc oxides to the aluminum silicate surface resulted in a sulfur capacity of 1226 mg S/g of catalyst. These findings provide critical insights for the development of catalysts that combine metal oxides to increase adsorption while reducing the production of byproducts like dimethyl sulfide (DMS) and dimethyl disulfide (DMDS) during methyl mercaptan removal.