(693f) Cargen® Technology: A Scalable Reforming Solution for Decarbonizing Gtl and Aviation Fuel Production

CARGEN®, a novel advanced dry reforming technology, enables the co-production of synthesis gas and high-value multi-walled carbon nanotubes (MWCNTs) while directly utilizing carbon dioxide as a feedstock. Developed to overcome the limitations of conventional autothermal reforming (ATR) and dry reforming of methane (DRM), CARGEN® demonstrates superior CO₂ conversion rates (up to 65% per pass) and economic viability through valuable carbon byproducts. This study investigates the deployment of CARGEN® across three integrated applications: retrofitting gas-to-liquid (GTL) plants, producing low-carbon aviation fuels (LCAF), and reducing energy demands through heat integration.

In a 50,000 bbl/day GTL plant simulation, replacing the ATR unit with CARGEN® reduced net CO₂ emissions by 73% and enabled the co-production of 243 kg of MWCNTs per barrel of syncrude. A hybrid LCAF configuration integrating solar power and CARGEN® achieved a net-negative carbon intensity of –138.9 g CO₂-eq/bbl, exceeding CORSIA requirements and supporting global decarbonization targets. Furthermore, process optimization using pinch analysis and algebraic techniques reduced indirect emissions by over 50%, addressing energy penalties often associated with reforming technologies.

Economic assessments indicate payout periods of less than 10 years, driven by diversified revenue from fuel and MWCNTs, even under moderate natural gas and carbon credit pricing. These findings highlight CARGEN® as a versatile, policy-relevant, and scalable decarbonization technology for the energy and aviation sectors, bridging the gap between sustainability and profitability in carbon-intensive industries.