High Technology Readiness Level Research Articles

Hands-Free Haptic Navigation Devices for Actual Walking.

In this survey, we give an overview of hands-free haptic devices specifically designed for navigation guidance while walking. We present and discuss the devices by body part, namely devices for the arm, foot and leg, back, belly and shoulders, waist and finally the head. Although the majority of the experimental tests were successful in terms of reaching the target while being guided by the device, the experimental requirements were wide-ranging. The distances to be covered ranged from just a few meters to more than a kilometer, and while some of the devices worked autonomously, others required the experimenter to act as Wizard of Oz. To compare the usefulness and potential of these devices, we created a table in which we rated several relevant aspects such as autonomy, conspicuity and compactness. Major conclusions are that outdoor devices have the highest technology readiness level, because these allow autonomous navigation through GPS, and that the most compact devices still require the action of an experimenter. Unfortunately, none of the hands-free devices are at a level of readiness where they could be useful to people with visual impairments. The most important factor that should be improved is localization accuracy, which should be high and available at all times.

Different behavior of two strains of the arbuscular mycorrhizal fungus Rhizophagus intraradices on Senecio bonariensis Hook. & Arn. against heavy metal soil pollution: a pilot-scale test

Arbuscular mycorrhizal fungi (AMF) have different biological mechanisms to alleviate stressful conditions in heavy metals (HMs) polluted soil. These mechanisms were widely assessed under controlled/greenhouse conditions, but scarcely studied at pilot or territory scale. The aim of this study was to evaluate the response of two Rhizophagus intraradices strains isolated from soils with different histories of pollution, in association with Senecio bonariensis plants, growing in an engineering vegetal depuration module filled with artificially HMs polluted substrate. Plants inoculated with GC3 strain uptook low amounts of HMs and translocated them to shoot biomass. Heavy metals (Mg, Zn, Mn, Cr, Cu and Ni) and macronutrients (Ca, K, S and P) were accumulated in roots of S. bonariensis when inoculated with GB8 strain, limiting their translocation to the shoot. Uninoculated plants showed high translocation of all studied elements to shoot tissues. Concluding, tested R. intraradices strains have exhibited different phytoprotection mechanisms under extremely toxic concentrations of HMs. Moreover, the development of the assay at such a high Technological Readiness Level represents a novel contribution in this field of study.

Redox-neutral electrochemical decontamination of hypersaline wastewater with high technology readiness level.

Industrial hypersaline wastewaters contain diverse pollutants that harm the environment. Recovering clean water, alkali and acid from these wastewaters can promote circular economy and environmental protection. However, current electrochemical and advanced oxidation processes, which rely on hydroxyl radicals to degrade organic compounds, are inefficient and energy intensive. Here we report a flow-through redox-neutral electrochemical reactor (FRER) that effectively removes organic contaminants from hypersaline wastewaters via the chlorination-dehalogenation-hydroxylation route involving radical-radical cross-coupling. Bench-scale experiments demonstrate that the FRER achieves over 75% removal of total organic carbon across various compounds, and it maintains decontamination performance for over 360 h and continuously treats real hypersaline wastewaters for two months without corrosion. Integrating the FRER with electrodialysis reduces operating costs by 63.3% and CO2 emissions by 82.6% when compared with traditional multi-effect evaporation-crystallization techniques, placing our system at technology readiness levels of 7-8. The desalinated water, high-purity NaOH (>95%) and acid produced offset industrial production activities and thus support global sustainable development objectives.

Laser powder bed fusion of high-strength low-alloy steels with post-heat treatment design for enhanced mechanical performance

A commonly used structural steel, namely high-strength low-alloy (HSLA) steel, HSLA-100, was fabricated using the laser powder bed fusion process in this work. Critical processing parameters such as laser power and scanning speed for achieving the least porosity were identified. The designed post-heat treatment differs from the traditionally manufactured HSLA steels. The optimum homogenization time was 80 min at 950 °C with the lowest prior austenite grain size. The peak hardness was achieved after tempering at 550 °C for 5 h, and atom probe tomography showed that the fraction of Cu and M2C (M: Mo, Cr) was the highest along with the co-precipitation of these strengthening phases at this condition. The yield strength (YS) and elongation (%El) of the builds printed with optimized parameters (porosity∼0.5%, YS = 875 MPa, and %El = 23%) were superior to those printed with factory-default parameters (porosity∼3%, YS = 772 MPa, and %El = 15%) after applying the designed post-heat treatment. Despite the anisotropy observed in the low-temperature toughness, the ductile-to-brittle transition temperature is below −40 °C for samples with a notch in the XZ plane and between −20 and −40 °C for samples with a notch in the XY plane. This work demonstrates the successful adaptation of HSLA-100 steel in additive manufacturing, and thus is critical for scaling up engineering applications at a higher technology readiness level.

Electrostatic Dust Analyzer for Dust Transport Measurements on the Lunar Surface

Lunar dust charging and transport is a more than five-decade-old problem. A high-fidelity and flight-qualified Electrostatic Dust Analyzer (EDA) has been developed to measure the charge, velocity, mass (size), and flux of electrostatically lofted dust particles on the lunar surface. Recent laboratory findings have greatly advanced our fundamental understanding of the dust-charging and -lofting mechanisms, providing critical constraints to the design of the EDA instrument. EDA consists of two identical dust trajectory sensor (DTS) units on both ends of the instrument with a deflection field electrode (DFE) unit lying in between. When a dust particle enters the instrument, charge signals induced on four arrays of wire electrodes in the two DTS units determine the total charge of the dust particle and its trajectory passing through the instrument from which the dust velocity vector is measured. The mass (size) is derived from the deflection of the dust trajectory by the DFE. A dust campaign was performed to characterize the instrument’s performance. The results meet or exceed the requirements. EDA has achieved high Technology Readiness Level 6. EDA measurements are important for assessing the dust environment on the lunar surface and its subsequent impact on crew safety and the operation of exploration systems. Additionally, EDA measurements are expected to have important implications for the surface evolution of all airless bodies, including the Moon and asteroids, in the solar system.

Using spectral sensing in plant science

Digital cameras are widely used tools for plant monitoring in plant science today. Used to track plant growth or even visible symptoms, they are important tools for breeding and plant protection field trials. Nevertheless, its extension to measure the near infrared (NIR) region (700–1000 nm) includes great potential as plants show a higher light reflectance within this spectrum. Various applications have shown its use for disease detection, quantification, virus content estimation, and stress monitoring. As the next step is a comprehensive integration into agricultural routines, this study will show two use-cases with a high technological readiness level. One use-case shows a handheld multispectral sensor, which is used for manual measurements to detect and discriminate different virus types in sugar beet. In contrast, the second use-case shows a transfer to an UAV based disease quantification routine based on spectral imaging for Cercospora leaf spot. In addition, two prototypical workflows are shown for processing non-imaging and imaging spectral data in an agricultural setting. This study shows the state of the art in spectral sensing in the field for the two major sugar beet diseases – virus yellows and Cercospora leaf spot. Furthermore a future perspective for coming technological challenges regarding the integration of AI in sensors or robotic workflows is provided.

Different approaches to analyze the impact of future climate change on the exploitation of wave energy

The increment of the share of renewable energies in the global mix implies that all renewable energies must be exploited. In this sense, it is necessary to make significant research and investment effort in the particular case of wave energy to reach the degree of maturity of other marine energies in the near future. Apart from the inherent factors that hinder the development of wave energy, such as the non-existence of a market-leading type of capturing device, uncertainties about the available future resource also hamper its growth. In this article, a review of the procedures followed in the literature to deal with the future wave energy resources and their subsequent exploitation is described. These procedures include the evaluation of the best future atmospheric models to drive wave models, the different downscaling techniques to evaluate the resource in large regions with high spatial resolution, and the analysis of the variability of the future energy resource and its future exploitability in a certain region taking into account different types of devices. Additionally, the current state of the art of previous studies dealing with future wave energy resources for different locations worldwide is described. Despite the difficulties involved in studying future wave energy resources, the high technological readiness level of the offshore wind industry, the creation of power generation farms with combined technologies, and the growth of marine aquaculture in the coming years could generate synergies that provide the definitive impulse to achieve the necessary technological development.

SURG-10. DEVELOPMENT OF 2 COMPLEMENTARY INNOVATIVE APPROACHES FOR REAL-TIME, LABEL-FREE INTRAOPERATIVE TUMOR DETECTION TO ENHANCE EXTENT OF RESECTION OF LOW GRADE GLIOMAS

Abstract Brain tumor surgery aims to maximize tumor resection while avoiding neurological deficits. Accurate characterization of tissue and delineation of resection margins are essential to achieve optimal surgical outcome. Hyperspectral imaging (HSI) and Real-time Rapid Evaporative Ionization Mass Spectrometry ( REIMS) are both novel technological adjuncts able to accurately detect intraoperatively zones of low grade glioma without substantially altering the surgical work flow. For HSI, we successfully demonstrate how an HSI system can interface with a clinically approved surgical microscope making use of the microscope’s available light sources and optical ports. We integrated the HSI system into the clinical workflow during brain surgery, specifically for resections of low-grade gliomas (LGG). During the study the acquired dataset was used to train an AI algorithm to detect LGG, providing 81% accuracy on unseen data. Real-time Rapid Evaporative Ionization Mass Spectrometry (REIMS) enables in-situ tissue characterization based on the mass spectrometric analysis of electrosurgical vapors generated during dissection. We demonstrate the use of REIMS for the molecular characterization of brain tumor tissue, thereby providing quasi real-time assessment of tumor type. A classification model containing 31 sampling points in normal brain tissue and 93 in glial tumor tissue provided 89.3% sensitivity and 91.1% specificity. Both techniques, HSI and REIMS display a high intraoperative diagnostic accuracy in terms of glioma tissue detection and are complementary, real-time and label-free methods which we developed and tested up to the stage of high Technology Readiness levels (TRL) of 7 and 5 respectively.

Economic analysis with multiscale high-throughput screening for covalent organic framework adsorbents in ammonia-based green hydrogen separation

Because green ammonia is an emerging transportation medium for carbon-free hydrogen, technologies for efficient and cost-effective separation and purification of green hydrogen have attracted significant attention in recent years. Among the various options for hydrogen separation, pressure swing adsorption (PSA) has the highest technology readiness level, but the optimal adsorbent for this application is still under investigation. This study evaluates the viability of covalent organic framework (COF) adsorbents for ammonia-based green hydrogen separation processes. The feasibility of the adsorbents was estimated based on the economic analysis of the entire green hydrogen production process with a newly proposed multiscale high-throughput screening (HTS) approach. This approach addresses an existing knowledge gap, where the molecular- and process-scale viewpoints are not fully considered together during adsorbent evaluation. The proposed HTS approach incorporates a new algorithm for simulations with reduced computational cost and a procedure for estimating the economic viability of the adsorbents. The results show that among 648 COFs in a COF database, MPCOF was the most efficient for ammonia-based green H2 separation with a H2 recovery of 72% and levelized cost of USD 8.30/kg H2. This result was obtained with only 31% of the computational cost required by an existing HTS approach.

Applying real options with reinforcement learning to assess commercial CCU deployment

Carbon capture and utilization (CCU), which emerged as a means to reduce anthropogenic carbon emissions, has been highlighted to close the carbon cycle and combat climate change. CCU involves utilizing or converting captured CO2 to create value-added products that can replace or supplement fossil fuel-derived products. In order to meet climate goals, commercial-scale CCU facilities need to be built and their capacities increased, but barriers to large-scale CCU deployment still exist, primarily caused by large uncertainties in product/energy prices, markets, technologies, and policies. Conventional techno-economic analysis (TEA) methods cannot appropriately assess viability of CCU deployment projects which include dynamic uncertainties and deployment strategies. More flexible methods that can account for both time-varying uncertainties and dynamic capacity building are needed. We propose a systematic framework for the evaluation of commercial CCU deployment using the theory of real options and reinforcement learning (RL). RL is needed as considering options of adding capacities or delaying/abandoning the project at multiple time points under dynamic uncertainties lead to a large-scale stochastic optimal control problem which cannot be solved using conventional optimization methods like stochastic programming. The framework consists of three steps: surrogate modeling, uncertainty modeling, and assessment modeling. The framework is dependent on the type of CCU technology, uncertainties, real options and RL algorithm. We demonstrate the application of the framework through a case study of CO2 hydrogenation-to-methanol process in Europe, which is a late-stage, i.e., high technology readiness level (TRL), technology.

High Temperature Superconductivity Application Readiness Map - Energy Delivery - Transmission, Substation and Distribution

The International Energy Agency's High Temperature Superconductivity Technology Collaboration Program (IEA HTS TCP) analyzed energy delivery applications for HTS. The product was a Readiness Map that illustrates the Technology Readiness Levels (TRL) over time of HTS applications. Assessing these TRL levels is important since the electric power system that supplies our residential, commercial and industrial sectors is experiencing a transition to safer, more efficient and cleaner power supply. The international experts assessed the present degree of technological development of the main transmission, substation and distribution HTS applications in the energy delivery sector and estimated the pathway to commercialization phase. Instead of using a specific TRL number 1-9 for each of the applications, they are categorized into low, medium and high TRL levels. Superconducting fault current limiters and medium voltage AC cables to interconnect substations at the low side of the transformer are currently at a high TRL as they can be purchased in the market. High voltage AC and DC cables are at a medium TRL and could reach a high level TRL level in 2030-2035. Superconducting transformers are at a low TRL and they could reach a high TRL level by 2030-2035.

Low‐Temperature Electrochemical Ammonia Synthesis: Measurement Reliability and Comparison to Haber–Bosch in Terms of Energy Efficiency

Recently, several studies have paved a way to nearly 100% selectivity of the electrochemical ammonia synthesis (EAS), which had been identified earlier as a main challenge. These results motivate us to benchmark the energy efficiency (EE) of EAS against the Haber–Bosch process for EAS works published in 2020, 2021, and 2022. A method is presented to estimate EE of EAS, which can be used by a broader audience. EAS studies historically suffered from reliability issues, and to avoid benchmarking of false‐positive results, a method is established to calculate a reliability indicator to assess the measurement reliability of a published work. The EE of EAS is calculated for works that are assessed as reliable with the indicator. Several promising systems and strategies enabling higher selectivity and EE are identified and discussed. The EE of some aqueous EAS reports is up to 55%, and nonaqueous is below 15%. However, while nonaqueous media reports suffer from low energy efficiency, they demonstrate much higher technology readiness levels (TRL) and total ammonium produced. Aqueous media reports have a great potential for higher energy efficiency, but they are at much lower TRL and total ammonia quantities produced are low.

Experimental Research in Synthetic Molecular Communications – Part I

Since its emergence from the communication engineering community around one and a half decades ago, the field of Synthetic Molecular Communication (SMC) has experienced continued growth, both in the number of technical contributions from a vibrant community and in terms of research funding. Throughout this process, the vision of SMC as a novel, revolutionary communication paradigm has constantly evolved, driven by feedback from theoretical and experimental studies, respectively. It is believed that especially the latter ones will be crucial for the transition of SMC towards a higher technology readiness level in the near future. In this spirit, we present here a comprehensive survey of experimental research in SMC. In particular, this survey focuses on highlighting the major drivers behind different lines of experimental research in terms of the respective envisioned applications. This approach allows us to categorize existing works and identify current research gaps that still hinder the development of practical SMC-based applications. Our survey consists of two parts; this paper and a companion paper. While the companion paper focuses on SMC with relatively long communication ranges, this paper covers SMC over short distances of typically not more than a few millimeters.

Unmanned rotating equipment for normally unattended installations

Offshore oil and gas operators are facing unprecedented challenges due to the need to reduce operational expenditure while operating in harsh/remote environments with an ever-increasing focus on safety and carbon footprint reduction. Technological innovation, especially around digitalisation and control, is a game changer that gives customers the opportunity to adopt low-manned or totally unmanned solutions without compromising cybersecurity standards. According to some operators, every employee removed from an offshore platform can result in approximately US$1 M savings per year. Additionally, mobilisation of personnel offshore is very risky. For these reasons, de-manning is a solution both for new projects and for units in operation. Developing unmanned trains for power generation and compression requires the introduction of different solutions: hardware and control system modifications; surveillance systems and digital services for advanced degradation monitoring. Systems should be designed considering three main development streams: (1) fully automatic start-up/shut-down, (2) no routine maintenance during operation and (3) no on-condition maintenance. This paper describes the Unmanned Rotating Equipment Package Solution developed by Baker Hughes in collaboration with primary offshore operators. We demonstrate a high technology readiness level; potential fast deployment at industrial scale and identify no main technological showstoppers. Maintenance activities requiring personnel on site can be carried out during campaign visits, currently scheduled every 6 months with the target to achieve one visit per year. In addition to benefits due to reduction or remote execution of on-site tasks, unmanning can bring further advantages to a project such as increased safety, lower carbon footprint and reduced total cost of ownership.

A Novel Analysis of Energy Density Considerations and Its Impacts on the Cost of Electrical Energy Storage (EES) Plants

Geological restrictions and the low energy density of compressed air energy storage (CAES) plants constitute a technical and economic barrier to the enablement of variable and intermittent sustainable sources of energy production. Liquid air energy storage (LAES) and pumped thermal energy storage (PTES) systems offer a promising pathway for increasing the share of renewable energy in the supply mix. PTES remains under development while LAES suffers from low liquefaction unit efficiency, although it is at a higher technology readiness level (TRL) than PTES. The most significant element of large-scale EES is related to the discharge features of the power plants, especially the energy storage unit. Here, a novel multi-aspect equation, based on established codes and thermodynamic principles, is developed to quantify the required storage capacity to meet demand consistent with the design parameters and operational limitations of the system. An important conclusion of the application of the multi-aspect equation shows that liquid air storage systems instead of compressed air would reduce the space required for storage by 35 times. Finally, a cost equation was introduced as a function of the required storage volume. Calculations have demonstrated that the use of the novel cost equation, in lieu of the old one-aspect cost equation, for an LAES power plant with a production capacity of about 50 MW makes the costs of installing liquid air storage tanks against the total expenditure of the power plant about six times higher than what was reported in earlier research.

Recent progress of applied TiO2 photoelectrocatalysis for the degradation of organic pollutants in wastewaters

Photoelectrocatalysis (PEC) is a promising powerful electrochemical advanced oxidation process (EAOP) that combines photocatalysis and electrolysis. Upon light irradiation over a semiconductor photocatalyst, electrons of its valence band are promoted to its conduction band giving rise to positively charged holes. The external bias potential applied to the photoanode extracts the photoexcited electrons toward the cathode of the electrolytic cell. Organics can then be oxidized directly by the holes or with hydroxyl radical formed by their reaction with H2O/OH−, and at lesser extent with other reactive oxygen species formed. The extensive study of TiO2 photoanodic nanomaterials and their applicability in environmental remediation makes necessary a further analysis of the state of the art and the actual understanding of potentials and shortcomings. This paper presents a comprehensive and critical review on the application of PEC with TiO2 photoanodes to remove organic pollutants from wastewaters from 2017 to May 2022. Fundamentals of this technique with pristine TiO2 photoanodes are explained, with special emphasis on the understanding of ROS origination mechanisms and the analytical techniques used for their characterization. Typical PEC systems and key operating variables related to the effectiveness of the process are examined. Recent advances obtained by TiO2 and TiO2-based photoanodes treatment of chemicals, dyes, pharmaceuticals, and pesticides are described and discussed. The preparation of TiO2 nanocomposites and their heterojunction mechanism, as well as the application of hybrid processes are detailed. Finally, prospects are proposed for the future research of PEC with perspectives to industrial application at higher technology readiness level.

Experimental Study of Impact of In-Service Deterioration on Aerodynamic Performance of High-Pressure Nozzle Guide Vanes

AbstractIn this paper we experimentally evaluate the impact of in-service deterioration on the aerodynamic performance of heavily film-cooled high-pressure nozzle guide vanes from large civil jet engines. We study 15 mid-life to end-of-life parts removed from operational engines, and compare their performance to those of new parts. Deterioration features included: increased surface roughness; thermal barrier coating spallation; damaged film cooling holes; and trailing edge burn-back. We characterize and present statistics for the surface roughness. Aerodynamic measurements were performed in the high technology readiness level Engine Component AeroThermal (ECAT) facility at the University of Oxford, at engine-representative conditions of exit Mach number, exit Reynolds number, coolant-to-mainstream pressure ratio, and turbulence intensity. We present detailed experimental measurements of the coolant capacity characteristics, downstream loss, and downstream flow structures. The results show that service time has the following effects on high-pressure nozzle guide vanes: increased equivalent sandgrain roughness of (up by 1056% change); reduced coolant flow capacity (maximum change of −6.27% for film cooling holes and −24.7% for the trailing edge slot); increased overall mixed-out kinetic energy loss coefficient by (up to 33% change); leads to greater downstream flow angle variation (change of −6 deg). This is one of the first significant studies of its type in the open literature, and is an important step towards whole-life engine performance assessment.

Valorization of Anaerobic-Fermentation Liquid Digestates—Membrane-Based Process Development

Complete valorization of various wastes and effluents, with significant organic content, remains a great challenge in the pursuit of a circular economy. The approach based on anaerobic fermentation, leading to valuable biogas production, has been broadly accepted and employed as an attractive processing scheme. However, despite notable research efforts, complete valorization of the digestates (involving recovery of nutrients/by-products and full recycling/reuse of treated water) requires additional work for sustainable process development. This study aims to make a contribution in this direction by demonstrating a systematic methodology for valorizing the liquid digestate. The proposed membrane-based processing scheme involves UF-membrane pretreatment of the liquid digestate (for sludge separation) and subsequent NF/RO membrane treatment for reuse/recycling of the permeate; the concentrate, enriched in "nutrients" (phosphate and ammonium compounds), can be utilized for soil fertilization, with further conditioning/processing. By performing targeted laboratory experiments and advanced simulations, the membrane-based process was developed to a relatively high technology-readiness level, including a pilot unit design/construction and preliminary testing with satisfactory results. Through pilot testing in industrial environment, further process development and optimization will be pursued, towards practical applications. The demonstrated methodology is also considered appropriate for systematic development of membrane-based processes to valorize/treat a variety of similar effluents.

Smart Glasses for Supporting Distributed Care Work: Systematic Review.

Over the past 2 decades, various desktop and mobile telemedicine systems have been developed to support communication and care coordination among distributed medical teams. However, in the hands-busy care environment, such technologies could become cumbersome because they require medical professionals to manually operate them. Smart glasses have been gaining momentum because of their advantages in enabling hands-free operation and see-what-I-see video-based consultation. Previous research has tested this novel technology in different health care settings. The aim of this study was to review how smart glasses were designed, used, and evaluated as a telemedicine tool to support distributed care coordination and communication, as well as highlight the potential benefits and limitations regarding medical professionals' use of smart glasses in practice. We conducted a literature search in 6 databases that cover research within both health care and computer science domains. We used the PRISMA (Preferred Reporting Items for Systematic Reviews and Meta-Analyses) methodology to review articles. A total of 5865 articles were retrieved and screened by 3 researchers, with 21 (0.36%) articles included for in-depth analysis. All of the reviewed articles (21/21, 100%) used off-the-shelf smart glass device and videoconferencing software, which had a high level of technology readiness for real-world use and deployment in care settings. The common system features used and evaluated in these studies included video and audio streaming, annotation, augmented reality, and hands-free interactions. These studies focused on evaluating the technical feasibility, effectiveness, and user experience of smart glasses. Although the smart glass technology has demonstrated numerous benefits and high levels of user acceptance, the reviewed studies noted a variety of barriers to successful adoption of this novel technology in actual care settings, including technical limitations, human factors and ergonomics, privacy and security issues, and organizational challenges. User-centered system design, improved hardware performance, and software reliability are needed to realize the potential of smart glasses. More research is needed to examine and evaluate medical professionals' needs, preferences, and perceptions, as well as elucidate how smart glasses affect the clinical workflow in complex care environments. Our findings inform the design, implementation, and evaluation of smart glasses that will improve organizational and patient outcomes.

Fabrication of highly active and stable Ni/CeO2-nanorods wash-coated on ceramic NZP structured catalysts for scaled-up CO2 methanation

The production of synthetic natural gas from CO2 methanation using green H2 produced via water electrolysis is a promising pathway regarding both the curtailment of excess power by variable renewables and the mitigation of CO2 emissions. Several catalytic systems have been employed for thermocatalytic CO2 methanation in lab-scale, with Ni-based catalysts being amongst the most cost-effective and active materials. In this regard, we have recently demonstrated the remarkable low-temperature CO2 methanation activity of a nickel catalyst supported on ceria nanorods, ascribed to the augmented metal-support synergy. Herein, we report on a scaled-up process of CO2 methanation, involving; i) fabrication of a highly porous NZP-type ceramic substrate of Ba1+xZr4P6–2xSi2xO24 in the form of extruded pellets, ii) wash-coating of Ni/CeO2-nanorods catalyst on NZP pellets, iii) design and testing of scaled-up experiments under a scaling factor of 80:1 and 65:1 in terms of mass and volume of catalysts compared to lab-scale experiments, respectively. The as-synthesized catalyst exhibited remarkable performance under variable reaction conditions and stable behavior after 75 h. Remarkably, the structured catalyst attained a methane formation rate of 277 NL gNi−1 h−1, being higher to numerous values reported in relevant works. Equally importantly, it was disclosed that increased values of space velocity led to high temperature gradient in the catalytic bed, thereby favoring the generation of CO. Intriguingly, the morphological and structural characteristics of the used catalyst remained unaltered even after various on/off reaction cycles and the stability test, which is a promising finding toward scaling-up the process at higher technology readiness levels using real feed streams.