SBIR-STTR Award

To eliminate the release of ventilation air methane (VAM) associated with coal production, the core challenge is how to oxidize methane given the low concentrations. Precision Combustion, Inc. (PCI) proposes an innovative modular array combining three key elements: (1) short contact time, low thermal mass reactor design to achieve maximal total conversion in a small volume, (2) catalyst formulation and loading to minimize the required operating temperature of the catalytic oxidation, and (3) system design and architecture to maximize the degree to which released heat is retained and recirculated in between elements. In the program, the modular structure will be modelled and optimized through computational fluid dynamics and thermal modelling to maximize heat transfer, both through the solid and from solid to gas. Flow passage sizing, fin structures, material choice, and other design elements impact on thermal performance and pressure drop will be examined. PCI would then additively manufacture these optimized designs to produce the 3-D lattice heat transfer surfaces and catalytic support structure. Testing will proceed through stages of individual elements, to multi-element blocks, to fielded pilot scale systems demonstrating high conversion efficiency of VAM. To achieve success in the program, PCI has assembled a strong team of additive manufacturers, mine engineers with experience with mine ventilation and carbon control processes and economics, and consultants with deep knowledge of VAM based on surveys of mines both for coal production and other methane associated deposits such as trona. PCI has teamed with mining operators, faculty, and experts in the field to support development and implementation, including transition to a mine. The TRL of the current system is at 3 4 and will be at 6 at completion of this effort.

To eliminate the release of ventilation air methane (VAM) associated with coal production, the core challenge is how to oxidize methane given the low concentrations. Precision Combustion, Inc. (PCI) proposes an innovative modular array combining three key elements: (1) short contact time, low thermal mass reactor design to achieve maximal total conversion in a small volume, (2) catalyst formulation and loading to minimize the required operating temperature of the catalytic oxidation, and (3) system design and architecture to maximize the degree to which released heat is retained and recirculated in between elements. In the program, the modular structure will be modelled and optimized through computational fluid dynamics and thermal modelling to maximize heat transfer, both through the solid and from solid to gas. Flow passage sizing, fin structures, material choice, and other design elements impact on thermal performance and pressure drop will be examined. PCI would then additively manufacture these optimized designs to produce the 3-D lattice heat transfer surfaces and catalytic support structure. Testing will proceed through stages of individual elements, to multi-element blocks, to fielded pilot scale systems demonstrating high conversion efficiency of VAM. To achieve success in the program, PCI has assembled a strong team of additive manufacturers, mine engineers with experience with mine ventilation and carbon control processes and economics, and consultants with deep knowledge of VAM based on surveys of mines both for coal production and other methane associated deposits such as trona. PCI has teamed with mining operators, faculty, and experts in the field to support development and implementation, including transition to a mine. The TRL of the current system is at 3 4 and will be at 6 at completion of this effort.