Combined ZnO reduction and methane reforming for co-production of pure Zn and syngas in a prototype solar thermochemical reactor

Abstract Solar thermochemical conversion processes offer a promising avenue for storing intermittent solar energy into high value chemical products. A directly-irradiated packed-bed reactor was developed to experimentally investigate the solar thermochemical methane reforming combined with ZnO reduction for co-production of Zn and syngas in a single process. On-sun experiments were conducted to demonstrate reliable process operation and to identify optimal operating conditions, considering the impact of reduced and atmospheric pressures, temperatures, and inlet methane flow-rates. A pressure decrease enhanced net ZnO conversion at the expense of lowered syngas selectivity attributed to the CO2 increase because of insufficient gas residence time. Increasing temperature promoted syngas production rate, yield, ZnO and methane conversion at the expense of favored methane cracking which can be alleviated by lowering pressure. The maximum H2 and CO yields of 28.4 and 4.6 mmol/gZnO, and the maximum net ZnO conversion and methane conversion (67.3% and 57.6%) were achieved from non-isothermal tests. The calorific value of chemical products was upgraded by solar energy (U up to 1.31), and ηsolar-to-chemical = 3.9% was achieved. Pure and highly reactive metallic Zn was produced with well crystallized structure in micrometric size, demonstrating the feasibility of combined solar methane reforming and ZnO reduction for synthetic fuel production and sustainable Zn metallurgy.