Inlet baffle structural optimization and reforming performance of exhaust gas-fuel reformer for marine LNG engine

Abstract

The structural and boundary conditions are pivotal factors influencing the performance of the reformer. However, previous research primarily relied on tailored theoretical boundary conditions specific to the research requirements, often conducted in low airspeed conditions ranging from 700 ℃ to 1000 ℃. There is a lack of research focused on the complex and dynamic process of reforming hydrogen production process in reformers that handle exhaust gas components with high flow rates, high dilution, complex compositions, and low to medium temperatures (300 °C–600 °C) as boundary conditions. The objective of this study is to optimize the structure of the reformation reactor while exploring its hydrogen reforming characteristics. Therefore, this study focused on the simulation-based optimization design of an EGR reformer for marine natural gas engines. A comprehensive model was developed by coupling fluid flow, heat transfer, and surface reactions on a nickel-based catalyst. The accuracy of the model was validated through experimental data from a single-tube fixed-bed catalytic reforming experiment. The results highlighted the importance of the reformer design, with the optimal configuration incorporating two baffle plates positioned at angles of 15° and 35°. This design achieved the most uniform flow field and minimal pressure drop among the six investigated configurations. Furthermore, the study emphasized the significance of reforming gas composition in achieving high performance. The optimal reforming gas composition was found to have an M/O value of approximately 2 and an S/M value of approximately 1. This resulted in an outlet hydrogen concentration of approximately 18.8%, hydrogen yield of approximately 46.1%, methane conversion rate of approximately 66.2%, and an energy efficiency of 71%. It was observed that increasing the EGR rate led to a decrease in performance indicators, with a more pronounced effect observed at an M/O value of 1. This study provides valuable insights into the performance optimization of EGR reformers for marine natural gas engines. The findings offer guidance on selecting operational parameters to enhance efficiency and hydrogen production.