Transforming Greenhouse Gases into Industrial Feedstock
Funded through the Grand Challenge: Innovative Carbon Uses Round 1 in 2014, the University of California Riverside project aimed to develop a novel process for converting carbon dioxide into methanol using a bi-reforming approach. At the heart of the project was an innovative catalyst based on thermally stable pyrochlore materials that enabled the simultaneous reforming of CO2 and methane with steam to produce synthesis gas (syngas), a key precursor for methanol production. This bi-reforming process offers a dual benefit: it consumes two potent greenhouse gases while generating a valuable industrial chemical. Unlike conventional steam reforming, which relies solely on methane and emits CO2, the bi-reforming pathway integrates CO2 directly into the feedstock, reducing the carbon intensity of methanol.
The project focused on designing and testing a nickel-based pyrochlore catalyst capable of withstanding the high temperatures and oxidative conditions required for bi-reforming. Laboratory-scale experiments demonstrated that the catalyst maintained structural integrity and catalytic activity over extended operation, with minimal carbon deposition. The catalyst achieved near-equilibrium conversions of methane and CO2 at temperatures above 850°C, producing syngas with an ideal 2:1 hydrogen-to-carbon monoxide ratio for downstream methanol synthesis. Supported by detailed process modelling and life cycle analysis, the team showed that a commercial-scale plant using this technology could reduce Alberta’s industrial GHG emissions by up to one million tonnes per year, while producing 15,000 tonnes of methanol per day.
Engineering Methanol for a Cleaner Economy
The project’s integration of experimental research and process modelling helped bridge the gap between catalyst innovation and real-world application. Using Aspen Plus simulations and life cycle analysis tools, the team demonstrated that the bi-reforming process which could significantly reduce greenhouse gas emissions compared to conventional steam reforming. The pyrochlore-based catalyst, central to this approach, proved capable of maintaining high activity and structural stability under the extreme conditions required for syngas production. By achieving near-equilibrium conversions and producing a syngas stream with an ideal hydrogen-to-carbon monoxide ratio, the technology offers a viable pathway to low-carbon methanol. These findings not only validate the catalyst’s performance but also highlight the broader potential of bi-reforming as a scalable solution for industrial CO2 utilization.
What’s next?
Since project completion, the University of California Riverside has continued to explore catalytic pathways for low-carbon methanol production, with a focus on refining the bi-reforming process and improving catalyst performance. While the original pyrochlore-based catalyst demonstrated strong thermal stability and promising activity under lab-scale conditions, further development has shifted toward modelling and optimizing CO2 hydrogenation systems using copper-based catalysts. Recent studies from the university have applied advanced theoretical frameworks to better understand reaction mechanisms and improve catalyst efficiency under industrial conditions. While they did not deploy in Alberta, the University program is still active.