The Sabatier reaction or Sabatier process was discovered by the French chemist Paul Sabatier in 1897. It involves the reaction of hydrogen with carbon dioxide at elevated temperatures (optimally 300–400 °C) and pressures in the presence of a nickel catalyst to produce methane and water. Optionally, ruthenium on alumina (aluminium oxide) makes a more efficient catalyst. It is described by the following exothermic reaction:
- ∆H = −165.0 kJ/mol
- (some initial energy/heat is required to start the reaction)
It has been seen in a renewable-energy-dominated energy system to use the excess electricity generated by wind, solar photovoltaic, hydro, marine current, etc. to make hydrogen via water electrolysis and the subsequent application of the Sabatier reaction to make methane  In contrast to a direct usage of hydrogen for transport or energy storage applications, the methane can be injected into the existing gas network, which in many countries has one to two years of storage capacity . The methane can then be used on demand to generate electricity (and heat—combined heat and power) overcoming low points of renewable energy production. The process is electrolysis of water by electricity to create hydrogen (which can partly be used directly in fuel cells) and the addition of carbon dioxide CO2 (Sabatier process) to create methane. The CO2 can be extracted from the air or fossil fuel waste gases by the amine process, amongst many others. It is a low-CO2 system, and has similar efficiencies of today's energy system. A 6 MW power-to-gas plant went into production in Germany in 2013, and powered a fleet of 1500 Audi A3s.
International Space Station life support
Oxygen generators on board the International Space Station produce oxygen from water using electrolysis; the hydrogen produced was previously discarded into space. As astronauts consume oxygen, carbon dioxide is produced, which must then be removed from the air and discarded as well. This approach required copious amounts of water to be regularly transported to the space station for oxygen generation in addition to that used for human consumption, hygiene, and other uses—a luxury that will not be available to future long-duration missions beyond low Earth orbit.
NASA is using the Sabatier reaction to recover water from exhaled carbon dioxide and the hydrogen previously discarded from electrolysis on the International Space Station and possibly for future missions. The other resulting chemical, methane, is released into space. As half of the input hydrogen becomes wasted as methane, additional hydrogen is supplied from Earth to make up the difference. However, this creates a nearly-closed cycle between water, oxygen, and carbon dioxide which only requires a relatively modest amount of imported hydrogen to maintain.
Ignoring other results of respiration, this cycle looks like:
The released hydrogen would then be recycled back into the Sabatier reactor, leaving an easily removed deposit of pyrolytic graphite. The reactor would be little more than a steel pipe, and could be periodically serviced by an astronaut where the deposit is chiselled out.
The Bosch reaction would present a completely closed hydrogen and oxygen cycle which only produces atomic carbon as waste. However, difficulties maintaining its temperature of up to 600 °C and properly handling carbon deposits mean significantly more research will be required before a Bosch reactor could become a reality. One problem is that the production of elemental carbon tends to foul the catalyst's surface (coking), which is detrimental to the reaction's efficiency.
Manufacturing propellant on Mars
The Sabatier reaction has been proposed as a key step in reducing the cost of manned exploration of Mars (Mars Direct, Interplanetary Transport System) through in-situ resource utilization. Hydrogen is combined with CO2 from the atmosphere, with methane then stored as fuel and the water side product electrolyzed yielding oxygen to be liquefied and stored as oxidizer and hydrogen to be recycled back into the reactor. The original hydrogen could be transported from Earth or separated from Martian sources of water.
A variation of the basic Sabatier methanation reaction may be used via a mixed catalyst bed and a reverse water gas shift in a single reactor to produce methane from the raw materials available on Mars, utilizing carbon dioxide in the Martian atmosphere and water extracted from the Martian subsoil or atmosphere. A 2011 prototype test operation that harvested CO2 from a simulated Martian atmosphere and reacted it with H2, produced methane rocket propellant at a rate of 1 kg/day, operating autonomously for 5 consecutive days, maintaining a nearly 100% conversion rate. An optimized system of this design massing 50 kg "is projected to produce 1 kg/day of O2:CH4 propellant ... with a methane purity of 98+% while consuming 700 Watts of electrical power." Overall unit conversion rate expected from the optimized system is one tonne of propellant per 17 MWh energy input.
Detailed chemical reactions
The stoichiometric ratio of oxidizer and fuel is 2:1, for an oxygen:methane engine:
However, one pass through the Sabatier reactor produces a ratio of only 1:1. More oxygen may be produced by running the water-gas shift reaction in reverse, effectively extracting oxygen from the atmosphere by reducing carbon dioxide to carbon monoxide.
Another option is to make more methane than needed and pyrolyze the excess of it into carbon and hydrogen (see above section), where the hydrogen is recycled back into the reactor to produce further methane and water. In an automated system, the carbon deposit may be removed by blasting with hot Martian CO2, oxidizing the carbon into carbon monoxide, which is vented.[original research?]
This reaction is slightly exothermic, and when the water is electrolyzed, an oxygen to methane ratio of 2:1 is obtained.
Regardless of which method of oxygen fixation is utilized, the overall process can be summarized by the following equation:
Looking at molecular masses, we have produced 16 grams of methane and 64 grams of oxygen using 4 grams of hydrogen (which would have to be imported from Earth, unless Martian water was electrolysed), for a mass gain of 20:1; and the methane and oxygen are in the right stochiometric ratio to be burned in a rocket engine. This kind of in-situ resource utilization would result in massive weight and cost savings to any proposed manned Mars or sample-return missions.
- In situ resource utilization
- Microlith (catalytic reactor)
- Timeline of hydrogen technologies
- Steam reforming
- Fischer–Tropsch process
- Bioenergy and renewable power methane in integrated 100% renewable energy system, ,
- scénario négaWatt 2011 (France), ,
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- Methane generator on-board the ISS
- "METHANE PYROLYSIS AND DISPOSING OFF RESULTING CARBON" (PDF).
Hydrogen may be obtained from methane by pyrolysis in the temperature range 1000°-1200°C. The main reaction products are hydrogen and carbon, though very small amounts of higher hydrocarbons, including aromatic hydrocarbons are formed. The conversion efficiency is about 95% at 1200°C. One needs to distinguish between thermodynamic equilibrium conversion and conversion limited by kinetics in a finite reactor
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- Extraction of Atmospheric Water on Mars
- Zubrin, Robert M.; Muscatello, Berggren (2012-12-15). "Integrated Mars In Situ Propellant Production System". Journal of Aerospace Engineering. 26: 43–56. doi:10.1061/(asce)as.1943-5525.0000201. ISSN 1943-5525.
- Compact and Lightweight Sabatier Reactor for Carbon Dioxide Reduction