Numerical Evaluation of Heat Transfer and Conversion Efficiency by Tube Design and Flow Configuration for a Compact Steam-Methane Reformer

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In the chemical industry, hydrogen (H2) production through steam-methane reforming is a well-established process. With the growing demand for H-fueled vehicles and charging stations, there is a need for compact reformers with efficient heat transfer capabilities. In this study, computational fluid dynamics simulations were performed to evaluate the methane (CH4) conversion and heat transfer efficiency of various reformer designs. These designs include single, double, and triple tubes, each with parallel- and counter-flow configurations between the reformate feed and heat source. The findings revealed substantial disparities in methane conversion between the tube designs and flow configurations. Notably, the triple-tube design outperforms single and double tubes, exhibiting higher methane conversion and improved heat transfer efficiency. This superior performance is attributed to the larger wall area facing the heat source and additional heat recovery from the reformate flowing in the inner annulus. This led to the highest temperature at the catalyst exit among the cases, increasing methane conversion, and the lowest reformate temperature at the reformer tube exit, which is also beneficial for the subsequent water–gas shift reaction process. Installing external fins on the reformer tube provided a more effective enhancement of heat transfer than using internal fins in the catalyst section. Regardless of the tube design employed, the counter-flow configuration consistently enhanced the heat transfer efficiency, resulting in 4.6–11.9% higher methane conversion than the parallel-flow configuration. Consequently, the triple-tube design with the counter-flow configuration achieved the highest methane conversion, offering flexibility in the reformer design, including the potential for lower heat input and a reduced catalyst volume.