Membrane reformer technology for sustainable hydrogen production from hydrocarbon feedstocks

Abstract

Hydrogen (H2) is receiving growing interest as a clean energy carrier as the world’s energy system transitions towards net zero. Today, H2 is primarily produced from hydrocarbons using the steam methane reforming (SMR) process. This well-established method converts methane-rich gas into syngas, which is further treated with steam to increase H2 yield via the water-gas-shift (WGS) process. However, this conventional route results in high carbon intensity of 10 tons CO2/ton of H2. Therefore, there is a growing need for sustainable H2 production technologies that utilize existing fossil energy sources and infrastructure while minimizing carbon emissions and costs.Membrane reactors (MR) are a promising technology for sustainable H2 production from hydrocarbons. A H2-selective palladium-alloy (Pd–Au) membrane is integrated within the catalyst bed, creating a system where H2 production and separation occur simultaneously in a single unit. This integration offers several advantages over the conventional system; process intensification allows thermodynamic equilibrium conversion limitations to be overcome while producing high purity (>99%) H2 at milder operating temperatures of ∼550 °C compared to 800–1000 °C in conventional packed bed reactors. Downstream processes such as WGS reactors and pressure swing adsorption are eliminated, resulting in reduced capital and operating costs. Moreover, the by-product stream remains pressurized at 25–40 bar and contains CO2 at concentrations above 60%, enabling CO2 capture at reduced cost.