Water-gas shift (WGS) reaction followed by carbon dioxide (CO<
sub>
2<
/sub>
) separation is a critical step in the integrated gasification combined cycle (IGCC) process for fossil-fuel-fired electrical power generation with CO<
sub>
2<
/sub>
capture. To intensify the IGCC process hydrogen-permselective zeolite membrane reactor offers promise to replace the conventional energy-intensive fixed-bed reactors and solvent-based CO<
sub>
2<
/sub>
capture units. The objectives of this project were to develop a bench-scale zeolite membrane reactor (total membrane area: 932 cm<
sup>
2<
/sup>
for a 21-tube membrane bundle) for the water-gas-shift reaction of raw syngas from an oxygen-blown coal-gasifier for H<
sub>
2<
/sub>
production with simultaneous CO<
sub>
2<
/sub>
separation at the capability of about 2 kilograms H<
sub>
2<
/sub>
per day (equivalent to 2 kW IGCC power plant) and to demonstrate significant progress toward achieving overall performance goal of 90% CO<
sub>
2<
/sub>
capture rate with 95% CO<
sub>
2<
/sub>
purity at the cost of electricity 30% less than the baseline carbon capture approaches. This report summarizes results obtained in this project on scaling up the zeolite membrane reactor by a factor of 200 in membrane area, tests of the bench-scale zeolite membrane reactor for the water-gas-shift reaction at high temperature and high-pressure, and techno-economic analysis of the integration of the zeolite membrane reactor in IGCC power plant for the electrical generation with CO<
sub>
2<
/sub>
capture. With effective pore modification by catalytic cracking deposition of MDES (methyldiethoxysilane), fabrication of MFI-type zeolite membranes was successfully scaled-up from a lab-scale disk type to bench-scale multiple-tube bundles on low-cost alumina supports. A Co-Mo based sour shift catalyst was evaluated and used in the zeolite membrane reactors for water-gas-shift reaction. The reaction kinetic and gas-permeation equations were developed and employed in mathematic models to guide/predict experiments/performance of zeolite membrane reactors for water-gas shift reaction. Multiple-tube zeolite membrane bundles and reactors were designed, fabricated and tested for gas separation and water-gas-shift reactions with real raw syngas from a coal-fired gasifier operated at high temperature and pressure. The zeolite membrane reactors demonstrated good long-term thermal and chemical stability and constant H<
sub>
2<
/sub>
permeance (>
300 GPU) together with a Knudsen selectivity (~4.7) for H<
sub>
2<
/sub>
over CO<
sub>
2<
/sub>
in the field test (cumulative time >
28 hours) with high-sulfur coal-derived syngas. The zeolite-membrane-reactor integrated IGCC process was designed using the performance experimentally measured by the University of Cincinnati team with a single-tube zeolite membrane reactor that offers a CO conversion >
98% with more than 90% of CO<
sub>
2<
/sub>
and H<
sub>
2<
/sub>
captured. With the above integrative approaches, a techno-economic analysis for a cost-benefit comparison was performed to uncover features that determine the power output, capital expenditure, operating expenditure, cost of electricity and cost of CO<
sub>
2<
/sub>
capture in a 550-MW zeolite-membrane-reactor integrated IGCC process. The integration of the zeolite membrane reactor in IGCC could provide a significant reduction of 80% and 27% in the power consumption for Selexol? Acid Gas Removal and CO<
sub>
2<
/sub>
compression, respectively, which lowers the total auxiliary power consumption by 12.5%. However, the low pressure required at permeate stream for maintaining the driving force of hydrogen permeation through the zeolite membrane costs a huge power in permeate compressor, compensating the power consumption reduction achieved with the membrane reactor. Thus, for coal-fired IGCC for electricity generation with 90% CO<
sub>
2<
/sub>
captured, the integration of the membrane reactor could provide a CO conversion ~99% and a significant drop in cost-of-electricity using zeolite membrane with H<
sub>
2<
/sub>
permeance >
600 GPU and the H<
sub>
2<
/sub>
/CO<
sub>
2<
/sub>
selectivity over 70.