Advancing Carbon Conversion with Membrane Reactor Technology
Funded through the Grand Challenge: Innovative Carbon Uses Round 1 in 2014, the Robert Gordon University project aimed to develop and demonstrate a novel flue gas catalytic membrane tri-reforming process that converts carbon dioxide (CO2) from industrial emissions into valuable synthesis gas, or syngas. This syngas—a mixture of hydrogen and carbon monoxide—can be used to produce high-value chemicals such as methanol, ammonia and synthetic fuels. The project focused on designing a compact, forced-flow catalytic membrane reactor capable of operating under real-world flue gas conditions, including the presence of contaminants such as sulphur dioxide (SO2) and nitrogen dioxide (NO2). By integrating methane with CO2, oxygen and water vapour already present in flue gas, the process offers a promising route to reduce emissions while generating commercially useful products.
Over the course of the project, the research team developed and tested a miniature prototype reactor, achieving 100 per cent conversion of both methane and carbon dioxide under optimized conditions. The system demonstrated strong mechanical stability, tolerance to flue gas impurities and scalability in membrane pore size and reactor dimensions. Economic modelling showed that hydrogen produced via the process could be significantly more cost-effective than conventional steam methane reforming, with the added benefit of lower greenhouse gas emissions. These results position the technology as a potential solution for Alberta’s industrial emitters, offering a pathway to reduce emissions while supporting economic diversification through value-added chemical production.
Enabling Scalable Carbon-to-Chemical Conversion
Building on its successful proof of concept, the Robert Gordon University team outlined a clear path toward scaling the technology for industrial deployment. The project demonstrated that the reactor design could be adapted for larger-scale applications by optimizing membrane pore size, reactor geometry and catalyst formulation. Economic modelling showed that hydrogen produced via flue gas methane reforming could be up to 100 per cent more cost-effective than conventional steam methane reforming, while also avoiding the need for costly CO2 capture and sequestration. With Alberta’s significant flue gas and methane resources, the process presents an opportunity to convert emissions into value-added products such as methanol, ammonia and synthetic fuels. The technology’s modular design, compatibility with existing infrastructure and potential for integration into petrochemical complexes position it as a possible solution for reducing emissions while supporting industrial growth.
What’s next?
Since project completion in 2017, Robert Gordon University has not progressed its F3R™ catalytic membrane reforming technology toward commercialization in Alberta. Although the final report proposed a phased development plan—including pilot-scale demonstrations and integration with natural gas combined cycle (NGCC) plants—the initiative did not attract the local industrial backing or investment needed to advance. While the project achieved promising lab-scale results and highlighted potential emissions reductions and cost advantages, the technology remained too early in its development to transition to commercial deployment. They developed a miniature prototype, but their technology was not sufficiently advanced, and they did not have enough local commitment to advance towards commercialization in Alberta. The carbon management program is still active at the university in the UK.