doi:10.1016/j.energy.2025.138183engPascual, S.Barón, C.Katla, D.Skorek-Osikowska, A.Wecel, D.Bailera, M.Legaz, J.Peña, B.Lisbona, P.Pilot-plant experimental tests and kinetic model validation of Ru-based catalytic methanation: assessment of operating pressure and filler material on carbon conversionART-2025-145421The production of synthetic methane is crucial for the energy transition in hard-to-electrify industries. This study assesses the reactor filler (Al2O3 and SiC) and operating pressure (1 and 4 bar) effects on methane performance of a commercial Ru-Al2O3 catalyst. Three catalytic methanation parameters are tested over a wide range: temperatures (200–450 °C), gas hourly space velocities (8000–120,000 h−1), and H2/CO2 molar ratios (3.5–5.5). Experiments are conducted in two pilot plants located at the Universidad de Zaragoza and the Silesian University of Technology. Results demonstrate a high level of reproducibility between the two pilot plants, using Al2O3 filler at 1 bar. Additionally, a kinetic model is validated with experimental measurements, showing an error margin of ±5 % between the model and experimental data. Regarding the effects of operational pressure and reactor filler, the best carbon conversion results are obtained with Al2O3 filler at 4 bar (up to 98 %). For both reactors, a 5 % reduction in carbon conversion is observed at 450 °C for SiC filler. Methane selectivity remains above 99 % in all cases, except for SiC filler at 1 bar (90 %). However, SiC filler shows better thermal diffusion, facilitating operational control.2025http://zaguan.unizar.es/record/16288810.1016/j.energy.2025.138183http://zaguan.unizar.es/record/162888oai:zaguan.unizar.es:162888info:eu-repo/grantAgreement/ES/AEI/RYC2022-038283-Iinfo:eu-repo/grantAgreement/ES/DGA/T46-17Rinfo:eu-repo/grantAgreement/ES/MCIU/FPU23-00073info:eu-repo/grantAgreement/ES/MICINN/PID2021-126164OB-I00Energy 335 (2025), 138183 [15 pp.]by-nc-ndhttps://creativecommons.org/licenses/by-nc-nd/4.0/deed.esinfo:eu-repo/semantics/openAccess