Numerical study on micro-reformer performance and local transport phenomena of the plate methanol steam micro-reformer

The objective of this work is to investigate the transport phenomena and performance of a plate steam methanol micro-reformer. Micro channels of various height and width ratios are numerically analyzed to understand their effects on the reactant gas transport characteristics and micro-reformer performance. In addition, influences of Reynolds number and geometric size of micro channel on methanol conversion of micro-reformer and gas transport phenomena are also explored. The predicted results demonstrated that better performance is noted for a micro channel reformer with lower aspect-ratio micro channel. This is due to the larger the chemical reaction surface area for a lower aspect-ratio channel reformer. It is also found that the methanol conversion decreases with increasing Reynolds number Re. The results also indicate that the smaller micro channel size experiences a better methanol conversion. This is due to the fact that a smaller micro channel has a much more uniform temperature distribution, which in turn, fuel utilization efficiency is improved for a smaller micro channel reformer.     

Optimal design of parallel channel patterns in a micro methanol steam reformer

This study describes the performance of micro methanol steam reformers with channel widths optimized using the simplified conjugate gradient method (SCGM), which uses a minimum objective function of the H₂ mass fraction standard deviation in channels. A three-dimensional numerical model and optimal simplified conjugate gradient algorithm were built to predict and search for the effects of channel widths and flow rate on the performance of chemical reactions. Furthermore, this simulation model was compared to; and corresponded well with existing experimental data. Distributions of velocity, temperature, and gas concentrations (CH₃OH, CO, H₂, and CO₂) were predicted, and the methanol conversion ratio was also evaluated. The mole fraction of CO contained in the reformed gas, which is essential to preventing poisoning of the catalyst layers of fuel cells, is also investigated. In the optimization search process, the governing equations use the continuity, momentum, heat transfer, and species equations to evaluate the performance of the steam reformer. The results show that channel width optimization can not only increase the methanol conversion ratio and hydrogen production rate but also decrease the concentration of carbon monoxide. The velocity and mixture gas density distributions in channels are discussed and plotted at various locations for an inlet liquid flow rate of 0.3 cc min⁻¹. Full development is not obtained in the downstream channel flow, the velocity in channel is increased from 1.28 m s⁻¹ to 2.36 m s⁻¹ at location Y = 1 mm–32 mm, respectively. This can be attributed to a continuous increase in the lightweight H₂ species as a result of chemical reactions in the channels.     

A micro reforming system integrated with a heat-recirculating micro-combustor to produce hydrogen from ammonia

In order to evaluate the potential of reforming ammonia as a carbon-free fuel in production of hydrogen, a new configuration of a micro reforming system integrated with a micro-combustor is studied experimentally. The micro-combustor as a heat source is a simple cylinder with an annular-type shield that applies a heat-recirculation concept. A micro-reformer to convert ammonia to hydrogen is an annulus, which is effective to transfer heat from the micro-combustor. The annulus-type micro reforming system is designed to produce 1-10 W (based on lower heating value, LHV) of hydrogen using various catalysts. The feed rate of ammonia, the micro-combustor inlet velocity of fuel-air mixtures and the catalyst materials substantially affect the performance of the designed micro reforming system. Under optimized design and operating conditions, the micro reforming system using ruthenium as a catalyst produces 5.4 W (based on LHV) of hydrogen with a conversion rate of 98.0% and an overall system efficiency of 13.7%. Thus, the present configuration can be applied to practical micro reforming systems, supporting the potential of using ammonia as a clean fuel.     

Poly-dimethylsiloxane (PDMS) based micro-reactors for steam reforming of methanol

A miniaturized methanol steam reformer with a serpentine type of micro-channels was developed based on poly-dimethylsiloxane (PDMS) material. This way of fabricating micro-hydrogen generator is very simple and inexpensive. The volume of a PDMS micro-reformer is less than 10 cm³. The catalyst used was a commercial Cu/ZnO/Al₂O₃ reforming catalyst from Johnson Matthey. The Cu/ZnO/Al₂O₃ reforming catalyst particles of mean diameter 50-70 μm was packed into the micro-channels by injecting water based suspension of catalyst particles at the inlet point. The miniaturized PDMS micro-reformer was operated successfully in the operating temperatures of 180-240 °C and 15%-75% molar methanol conversion was achieved in this temperature range for WHSV of 2.1-4.2 h⁻¹. It was not possible to operate the micro-reformer made by pure PDMS at temperature beyond 240 °C. Hybrid type of micro-reformer was fabricated by mixing PDMS and silica powder which allowed the operating temperature around 300 °C. The complete conversion (99.5%) of methanol was achieved at 280 °C in this case. The maximum reformate gas flow rate was 30 ml/min which can produce 1 W power at 0.6 V assuming hydrogen utilization of 60%.     

Micro-fuel cells—Current development and applications

The importance of micro-fuel cell has been increased with the demand for uninterrupted power source in today's power hungry portable electronics. Currently, there is aggressive research going on to commercialize the micro-fuel cell by many laboratories and companies. The three different fuels feeding systems, i.e. pure hydrogen, pure hydrocarbons (alcohol, i.e. methanol and ethanol; formic acid and ethylene glycol) and on-board hydrogen from reformed hydrocarbons like methanol or other compound like water can be used for operating the micro-fuel cells. The current status on the research and development of micro-fuel cell with all the above three types of fuels have been discussed. The different substrate materials used in micro-fuel cells for the suitability of the portable electronics have also been stated. The design aspects of micro-fuel cells and micro-reformers are discussed here. The current state of commercialization of micro-fuel cells for portable electronics has been reviewed based on the open literature. The hurdles to overcome in order to commercialize in full phase have been reported, whenever possible. Some very new technologies which can make the micro-fuel cell into a very promising system with a simple operation have also been focused.     

An annulus-type micro reforming system integrated with a two-staged micro-combustor

A new configuration of a micro reforming system integrated with a micro-combustor is studied experimentally and computationally. The micro-combustor as a heat source is a simple cylinder, which is easy to fabricate, but is two-staged (expanding downstream) to control ignition and stable burning. A micro-evaporator to vaporize methanol–water mixtures and a micro-reformer to convert the vaporized methanol–water mixtures to hydrogen are annuli, which are effective to transfer heat from the first and second-stage micro-combustors, respectively. The annulus-type micro reforming system is designed to produce 1–10 W (based on lower heating value, LHV) of hydrogen using the steam reforming method. The molar ratio of water to methanol, the feed rate of water–methanol mixtures, the micro-combustor inlet velocity of fuel–air mixtures and the micro-combustor materials substantially affect the performance of the designed micro reforming system. Under optimized design and operating conditions, the micro reforming system produces 6.9 W (based on LHV) of hydrogen with a conversion rate of 97.5%, an overall system efficiency of 39.7% and a carbon monoxide concentration of 6.7 ppm. Thus, the present configuration can be applied to practical micro reforming systems for use with fuel cells.     

Fabrication of flexible micro-sensors and flow field of stainless steel-based micro-reformer by micro-electro-mechanical-systems process

Recent advances in micro-fuel cells have increased the demand for hydrogen. Therefore, a micro-reformer must be developed. Numerous portable electric devices are extremely small and reformers must therefore be shrunk and combined with micro-fuel cells. The mass production of micro-reformers raises various problems that are yet to be solved, such as the measurement of their internal temperature and flow rate. Such issues influence the efficiency of the micro-reformers. To our knowledge, no investigation has yet properly elucidated the internal operation of micro-reformers. Accordingly, in this work, a flexible micro-temperature sensor, a micro-heater, a micro-flow sensor and the flow field of a stainless steel-based micro-reformer were fabricated by micro-electro-mechanical-systems (MEMS) fabrication technique. The fabrication technique has the advantages of (1) small size, (2) flexible but precise measurement positions, and (3) mass production process.     

Three-dimensional analysis of a plate methanol steam micro-reformer and a methanol catalytic combustor with different flow channel designs

Three-dimensional models of a plate methanol steam micro-reformer and a methanol catalytic combustor with parallel flow fields and serpentine flow fields have been established. The effects of the flow field design and the fuel flow rate on the methanol conversion and transport phenomena in the micro-reformer were investigated. The results revealed that the methanol conversion of the micro-reformer with the serpentine flow field and the combustor with the serpentine flow field has been optimized as a result of improved thermal management in the micro-reformer with combustor. With a change in flow field design from the micro-reformer and the combustor with parallel flow fields to the micro-reformer and combustor with the serpentine flow fields a wall temperature increase from 225 °C to 237 °C was observed. The methanol conversion of the micro-reformer with the serpentine flow field and the combustor with the serpentine flow field could be improved by 23% relative to the employment of a parallel flow field. A numerical model provided an efficient way to characterize the transport phenomena within the micro-reformer and combustor; the results will benefit the future design of plate methanol steam micro-reformers with combustors.     

Studies on a two-staged micro-combustor for a micro-reformer integrated with a micro-evaporator

A new micro-combustor configuration for a micro fuel-cell reformer integrated with a micro-evaporator is studied experimentally and computationally. The micro-combustor as a heat source is designed for a 10–15 W micro-reformer using the steam reforming method. In order to satisfy the primary requirements for designing a micro-combustor integrated with a micro-evaporator, i.e., stable burning in a small confinement and maximum heat transfer through a wall, the present micro-combustor is a simply cylinder, which is easy to fabricate, but is two-staged (expanding downstream) to control ignition and stable burning. The aspect ratio and wall thickness of the micro-combustor substantially affect ignition and thermal characteristics. For optimized design conditions, a pre-mixed micro-flame is easily ignited in the expanded second-stage combustor, moves into the smaller first-stage combustor, and finally is stabilized therein. The measured and predicted temperature distributions across the micro-combustor walls indicate that heat generated in the micro-combustor is well transferred. Thus, the present micro-combustor configuration can be applied to practical micro-reformers integrated with a micro-evaporator for use with fuel cells.     

A Methanol Steam Micro-Reformer for Low Power Fuel Cell Applications

A micro-reformer was fabricated and its performance investigated using copper-zinc catalysts with differing compositions and loadings at various operating conditions. A catalyst with 3:1 copper-to-zinc ratio and 8 wt% loading produced enough hydrogen to power a 28W PEM fuel cell when using a third of the reformer's volume (8 cm³) and assuming 64% fuel cell efficiency. Methanol conversion was 65% while hydrogen content in the off-gas was 45% at a temperature of 275°C and residence time of 0.11s. Carbon monoxide levels were approximately 1.45%. Higher methanol conversions (80%) and hydrogen content in the off-gas (50%) were achieved by a second catalyst with 16 wt% at 290°C while utilizing the entire reformer volume. Hydrogen yield and selectivity were high (78 and 98% respectively). Extrapolating from present results, the maximum power output possible to be achieved by this device is 84 W.