Millisecond methane steam reforming for hydrogen production: A computational fluid dynamics study

Abstract

The potential of methane steam reforming to produce hydrogen in thermally integrated micro-chemical systems at short contact times was theoretically explored. Methane steam reforming coupled with methane catalytic combustion in microchannel reactors for hydrogen production was studied numerically. A two-dimensional computational fluid dynamics model with detailed chemistry and transport was developed. To provide guidelines for optimal design, reactor behavior was studied, and the effect of design parameters such as catalyst loading, channel height, and flow arrangement was evaluated. To understand how steam reforming can happen at millisecond contact times, the relevant process time scales were analyzed, and a heat and mass transfer analysis was performed. The importance of energy management was also discussed in order to obtain a better understanding of the mechanism responsible for efficient heat exchange between highly exothermic and endothermic reactions. The results demonstrated the feasibility of the design of millisecond reforming systems, but only under certain conditions. To achieve this goal, process intensification through miniaturization and the improvement in catalyst performance is very important, but not sufficient; very careful design and implementation of the system is also necessary to enable high thermal integration. The channel height plays an important role in determining the efficiency of heat exchange. A proper balance of the flow rates of the combustible and reforming streams is an important design criterion. Reactor performance is significantly affected by flow arrangement, and co-current operation is recommended to achieve a good energy balance within the system. The catalyst loading must be carefully designed to avoid insufficient reactant conversion or hot spots. Finally, operating windows were identified, and engineering maps for designing devices with desired power were constructed.