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<p>Biogas upgrading to pipeline-grade methane (&gt;95% CH<sub>4</sub>) represents a critical pathway for enhancing the utilization and value of biogas. Direct methanation of biogas is promising, but due to the performance limitations of conventional nickel-based methanation catalysts, reactant circulating or multi-stage process is required as engineering compensation. Here, through process simulation and economic analysis, we demonstrate substantial economic benefits of the single-stage methanation process over conventional routes in terms of both capital investment and operation costs. A structured inverse catalyst with CeZrO<sub>x</sub>/Ni inverse configuration grown on porous Ni-foam featuring specific surface area and water removal enhancements over powder inverse catalyst is developed and realizes scale-up. The remarkable low-temperature activity of the structured inverse catalysts achieves a near-equilibrium conversion of 97.8% CO<sub>2</sub> in biogas, allowing the production of pipeline-grade methane through the single-stage biogas methanation process. With the innovation of catalysts and process, the price of low-carbon methane produced from biogas with industrial by-product hydrogen is competitive with natural gas.</p>

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Economical biogas direct methanation to pipeline grade natural gas via structured Ni based inverse catalyst

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年1月7日

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  • Xin Tang,
  • Xincheng Zhang,
  • Ziyu Song,
  • Chuqiao Song,
  • Yao Xu,
  • Xuguang Yang,
  • Yuanchang Wang,
  • Hanfeng Lu,
  • Siyu Yao,
  • Zuwei Liao,
  • Xiaonian Li,
  • Ding Ma,
  • Lili Lin

摘要

Biogas upgrading to pipeline-grade methane (>95% CH4) represents a critical pathway for enhancing the utilization and value of biogas. Direct methanation of biogas is promising, but due to the performance limitations of conventional nickel-based methanation catalysts, reactant circulating or multi-stage process is required as engineering compensation. Here, through process simulation and economic analysis, we demonstrate substantial economic benefits of the single-stage methanation process over conventional routes in terms of both capital investment and operation costs. A structured inverse catalyst with CeZrOx/Ni inverse configuration grown on porous Ni-foam featuring specific surface area and water removal enhancements over powder inverse catalyst is developed and realizes scale-up. The remarkable low-temperature activity of the structured inverse catalysts achieves a near-equilibrium conversion of 97.8% CO2 in biogas, allowing the production of pipeline-grade methane through the single-stage biogas methanation process. With the innovation of catalysts and process, the price of low-carbon methane produced from biogas with industrial by-product hydrogen is competitive with natural gas.