Exergy analysis of hydrogen production via steam methane reforming

The performance of hydrogen production via steam methane reforming (SMR) is evaluated using exergy analysis, with emphasis on exergy flows, destruction, waste, and efficiencies. A steam methane reformer model was developed using a chemical equilibrium model with detailed heat integration. A base-case system was evaluated using operating parameters from published literature. Reformer operating parameters were varied to illustrate their influence on system performance. The calculated thermal and exergy efficiencies of the base-case system are lower than those reported in literature. The majority of the exergy destruction occurs due to the high irreversibility of chemical reactions and heat transfer. A significant amount of exergy is wasted in the exhaust stream. The variation of reformer operating parameters illustrated an inverse relationship between hydrogen yield and the amount of methane required by the system. The results of this investigation demonstrate the utility of exergy analysis and provide guidance for where research and development in hydrogen production via SMR should be focused.     

Production of hydrogen by ethanol steam reforming over catalysts from reverse microemulsion-derived nanocompounds

In the present work, hydrotalcite-like compound precursor for preparing mixed oxide catalyst was successfully synthesized by a novel method, which was a combination of the reverse microemulsion and coprecipitation methods. It was observed that the precursor obtained from the above method possessed superior characteristics for preparing mixed oxide catalyst used in ethanol steam reforming (ESR). Furthermore, for comparison, catalysts prepared from conventional coprecipitation and impregnation methods had been characterized together with the catalyst prepared from the new method. Besides ICP, BET, X-ray diffraction (XRD), temperature-programmed reduction (TPR), H₂-TPD, TG, and TEM analytic techniques, catalytic performance for ESR was also investigated. The results of XRD and TPR indicated that a solid solution phase existed in the catalysts obtained from reverse microemulsion and coprecipitation methods, while spinel phase together with solid solution were observed in the catalyst obtained from the impregnation method. The high BET surface area of the catalyst obtained from the reverse microemulsion method enhanced the dispersion and the surface area of nickel, which improved the catalyst performance. From TEM images, the aggregated Ni could be found in the catalyst obtained from the impregnation method, while the hydrotalcite-like compound precursors prepared from reverse microemulsion and coprecipitation methods produced homogeneously distributed active Ni metal species. The catalyst obtained from reverse microemulsion exhibited the best activity, stability, and least carbon deposition because of the formation of hydrotalcite-like compound precursor, uniform dispersion of active Ni metal species, and much more surface area supporting the active Ni metal sites.     

Production of hydrogen via methane reforming using atmospheric pressure microwave plasma

In this paper, results of hydrogen production via methane reforming in the atmospheric pressure microwave plasma are presented. A waveguide-based nozzleless cylinder-type microwave plasma source (MPS) was used to convert methane into hydrogen. Important advantages of the presented waveguide-based nozzleless cylinder-type MPS are: stable operation in various gases (including air) at high flow rates, no need for a cooling system, and impedance matching. The plasma generation was stabilized by an additional swirled nitrogen flow (50 or 100 l min⁻¹). The methane flow rate was up to 175 l min⁻¹. The absorbed microwave power could be changed from 3000 to 5000 W. The hydrogen production rate and the corresponding energy efficiency in the presented methane reforming by the waveguide-based nozzleless cylinder-type MPS were up to 255 g[H₂] h⁻¹ and 85 g[H₂] kWh⁻¹, respectively. These parameters are better than those typical of the conventional methods of hydrogen production (steam reforming of methane and water electrolysis).     

Improvement of steam methane reforming via in-situ CO2 sorption over a nickel-calcium composite catalyst

Optimization of steam methane reforming (SMR) reaction by CO₂ sorption enhancement was investigated. In this study, the sorption-enhanced steam methane reforming reaction (SESMR) was conducted to maximize hydrogen production via suitable adjustments in the operating conditions of the reaction, which include the molar ratio of steam to CH₄, space velocity, and temperature. The reforming catalysts were prepared by a physical mixture of 20 wt% Ni/Al₂O₃ and CaO. The results reveal that there are significant differences in CH₄ conversion between the SMR and the SESMR from 18% to 108%; this conversion strongly depended on the reaction conditions. High-purity H₂ products (98.9%) with <0.1 ppmv CO were obtained by SESMR under the suitable conditions of 2600 cm³/g/h, steam/CH₄ molar ratio of 4 and 823 K. This implies that the high-quality H₂ produced through the SESMR process could be directly used for the proton-exchange membrane fuel cell.     

Thermodynamic analysis of hydrogen production for fuel cell via oxidative steam reforming of propane

A thermodynamic analysis of hydrogen production from propane by oxidative steam reforming (OSR) is performed with a Gibbs free energy minimization method. Addition of oxygen reduces the enthalpy of the system and facilitates the heat supply. Equilibrium compositions of OSR as a function of temperature (300, 500, 700 and 900 °C), H₂O/C₃H₈ ratio (1.0–20.0) and O₂/C₃H₈ ratio (0.0–2.0) under oxidative and thermo-neutral (TN) conditions are evaluated. The results for oxidative conditions demonstrate that at 700 °C with H₂O/C₃H₈ ratios above 7.0 and/or O₂/C₃H₈ ratios higher than 1.3 are beneficial for hydrogen production which facilitates superior hydrogen yield, i.e. close to 9.0 mol/mol propane, with coke and methane formation reactions being suppressed effectively. For TN condition, autothermal temperature and equilibrium composition have a stronger dependence on O₂/C₃H₈ ratio than on H₂O/C₃H₈ ratio. Further calculations show that the condition at 700 °C with an appropriate H₂O/C₃H₈ ratio between 7.0 and 13.0 is favorable for achieving a high hydrogen yield and a low carbon monoxide yield. Therefore, a favorable operational range is proposed to ensure the most optimized product yield.     

Numerical and experimental study on hydrogen production via dimethyl ether steam reforming

This work presents the characteristics of catalytic dimethyl ether (DME)/steam reforming based on a Cu–Zn/γ-Al₂O₃ catalyst for hydrogen production. A kinetic model for a reformer that operates at low temperature (200 °C–500 °C) is simulated using COMSOL 5.2 software. Experimental verification is performed to examine the critical parameters for the reforming process. During the experiment, superior Cu–Zn/γ-Al₂O₃catalysts are manufactured using the sol-gel method, and ceramic honeycombs coated with this catalyst (1.77 g on each honeycomb, five honeycombs in the reactor) are utilized as catalyst bed in the reformer to enhance performance. The steam, DME mass ratio is stabilized at 3:1 using a mass flow controller (MFC) and a generator. The hydrogen production rate can be significantly affected depending on the reactant's mass flow rate and temperature. And the maximum hydrogen yield can reach 90% at 400 °C. Maximum 8% error for the hydrogen yield is achieved between modeling and experimental results. These experiments can be further explored for directly feeding hydrogen to proton exchange membrane fuel cell (PEMFC) under the load variations.     

Production of hydrogen by steam reforming of phenol over Ni/Al2O3-ash catalysts

An improved method for hydrogen production by the steam reforming of phenol over novel fly ash-based catalysts is investigated. The Ni/Al₂O₃-ash catalysts are prepared by an equal-volume impregnation method and characterized by XRD, FESEM, BET and H₂-TPR techniques. The effects of various process parameters including mixing ratio of fly ash, temperature, support, gas hourly space velocity (GHSV) and steam-to-carbon molar ratio (S/C) on the catalytic activity are investigated. The results show that fly ash mixing at 50 wt% and choosing γ-Al₂O₃ as the support own the best performance. A maximum hydrogen yield of 83.8% is achieved at 450 °C with a S/C of 10 and a GHSV of 4968 h^?1 with a maximum phenol conversion of 98.6%. The stability of the Ni-ash1-γA1 catalyst is further investigated and it is shown to continuously and stably react for more than 20 h at 450 °C with excellent catalytic reaction stability.     

Hydrogen production via steam reforming of coke oven gas enhanced by steel slag-derived CaO

Steel slag, a waste from steelmaking plant, has been proven to be good candidate resources for low-cost calcium-based CO₂ sorbent derivation. In this work, a cheap and sintering-resistance CaO-based sorbent (CaO (SS)) was prepared from low cost waste steel slag and was applied to enhance catalytic steam reforming of coke oven gas for production of high-purity hydrogen. This steel slag-derived CaO possessed a high and stable CO₂ capture capacity of about 0.48 g CO₂/g sorbent after 35 adsorption/desorption cycles, which was mainly ascribed to the mesoporous structure and the presence of MgO and Fe₂O₃. Product gas containing 95.8 vol% H₂ and 1.4 vol% CO, with a CH₄ conversion of 91.3% was achieved at 600 °C by steam reforming of COG enhanced by CaO (SS). Although high temperature was beneficial for methane conversion, CH₄ conversion was remarkably increased at lower operation temperatures with the promotion effects from CaO (SS), and CO selectivity has been also greatly decreased. Reducing WHSV could increase methane conversion and reduce CO selectivity due to longer reactants residence time. Reducing C/A could increase methane conversion and hydrogen recovery factor, and also decrease CO selectivity. When being mixed with catalyst during SE-SRCOG, CaO (SS) with a uniform size distribution favored methane conversion due to the high utilization efficiency of catalyst. Promising stability of CaO (SS) in cyclic reforming/calcination tests was evidenced with a hydrogen recovery factor >2.1 and CH₄ conversion of 82.5% at 600 °C after 10 cycles using CaO (SS) as sorbent.     

Sustainable H2 generation via steam reforming of biogas in membrane reactors: H2S effects on membrane performance and catalytic activity

This study proposes the steam reforming of a synthetic biogas stream containing 200 ppm of H₂S, carried out in a non-commercial supported Pd–Au/Al₂O₃ membrane reactor (7–8 μm selective layer thickness) at 823 K and 150 kPa over a non-commercial Rh(1%)/MgAl₂O₄/Al₂O₃ catalyst. This system is able to recover almost 80% of the total hydrogen produced during the reaction and shows good resistance to the H₂S contamination, as confirmed by stable methane conversions for more than 400 h under operation. For comparison, the same reaction was carried out in a commercial self-supported Pd–Ag membrane (150 μm wall thickness), yielding a hydrogen recovery equal to 40% at 623 K and 200 kPa, and presenting stable methane conversions for less than 200 h under operation due to the effect of the H₂S contamination.     

Sustainability assessment of hydrogen production by steam reforming

A specific methodology was applied to investigate the expected impact on sustainability of processes for hydrogen production by steam reforming of natural gas. Reference process schemes based on the current industrial state-of-the-art and on innovative steam reforming technologies were defined and assessed. The methodology allowed the calculation of a sustainability “fingerprint” of the reference schemes, based on sustainability key performance indicators. The results obtained evidenced the potential advantages of innovative processes, based on integrated conversion and internal membrane separation reactors. However, the valorization of the by-product streams is an essential requirement to reduce the impact on sustainability of these processes. Besides the improvement of the reaction section, the optimization of the overall separation efficiency and of energy requirement emerged as the key elements that control the overall sustainability performance of these processes.     

Comparative analysis on sorption enhanced steam reforming and conventional steam reforming of hydroxyacetone for hydrogen production: Thermodynamic modeling

The chemical thermodynamics of sorption enhanced steam reforming (SESR) of hydroxyacetone for hydrogen production were investigated and contrasted with hydroxyacetone steam reforming (SR) by means of Gibbs free energy minimization principle and response reactions (RERs) method. Hydrogen is mainly derived methane steam reforming reaction from and water gas shift reaction. The former reaction contributes more than the latter one to hydrogen production below 550 °C and at higher temperature the latter one tends to dominate. The maximum hydrogen concentration is 70% in SR, which is far below hydrogen purities required by fuel cells. In SESR, hydrogen purities are over 99% in 525–550 °C with a WHMR greater than 8 and a CHMR of 6. The optimum temperature for SESR is approximately 125 °C lower than that for SR. In comparison with SR, SESR has the advantage of almost complete inhibition of coke formation in 200–1200 °C for WHMR ≥ 3.     

H2 production in silica membrane reactor via methanol steam reforming: Modeling and HAZOP analysis

The main aim of this work is the presentation of both qualitative safety and quantitative operating analyses of silica membrane reactor (MR) for carrying out methanol steam reforming (MSR) reaction to produce hydrogen. To perform the safety analysis, HAZOP method is used. Before the HAZOP analysis, a comprehensive investigation of most important operating parameters effects on silica MR performance is required. Therefore, for a quantitative analysis, a 1-dimensional and isothermal model is developed for evaluating the reaction temperature, reaction pressure, feed molar ratio (steam/methanol) and feed flow rate effects on silica MR performance in terms of methanol conversion and hydrogen recovery. The model validation results show good agreement with experimental data from literature. As a consequence, simulation results indicate that the reaction pressure and feed molar ratio have dual effect on silica MR performance. In particular, it is found that methanol conversion is decreased by increasing the reaction pressure from 1.5 to 4.0 bar, whereas over 4.0 bar, it is improved. Moreover, the hydrogen recovery is decreased by increasing the feed molar ratio from 1 to 5, while over 5, it was approximately constant. After the evaluation of modeling results, the HAZOP analysis for silica MR is carried out during MSR reaction. The analysed operating parameters in the modeling study have been considered as key parameters in the HAZOP analysis. The safety assessment results are presented in tables as check list. By considering the HAZOP results, safety pretreatment works are recommended before or during the experimental tests of MSR reaction in silica MR. According to different parameters consequences, reaction temperature is the most critical parameter in MSR reaction for the silica MR studied in this work. In particular, to avoid the consequences of temperature deviation, it is recommended to use a PID temperature controller in the silica MR for MSR reaction.     

Hydrogen production via chemical looping steam reforming of ethanol by Ni-based oxygen carriers supported on CeO2 and La2O3 promoted Al2O3

This work studies the effects of Ce⁴⁺ and/or La³⁺ on NiO/Al₂O₃ oxygen carrier (OC) on chemical looping steam reforming of ethanol for hydrogen production - alternating between fuel feed step (FFS) and air feed step (AFS). Suitable amount of Ce- and La-doping increases OC carbon tolerance. The solubility limit is found at 50 mol% La in solid solution. At higher La-doping, La₂O₃ disperses on the surface and adsorbs CO₂ forming La₂O₂CO₃ during FFS. From the 1st cycle, 12.5 wt%Ni/7 wt%La₂O₃-3wt%CeO₂–Al₂O₃ (N/7LCA) displays the highest averaged H₂ yield (3.2 mol/mol ethanol) with 87% ethanol conversion. However, after the 5th cycle, 12.5 wt%Ni/3 wt%La₂O₃-7wt%CeO₂–Al₂O₃ (N/3LCA) exhibits more stability and presents the highest ethanol conversion (88%) and H₂ yield (2.7 mol/mol ethanol). Amorphous coke on the OCs decreases with increasing La³⁺ content and can be removed at 500 °C during AFS; nevertheless, fibrous coke and La₂O₂CO₃ cannot be eliminated. Therefore, after multiple redox cycles, highly La-doped OCs exhibits rather low stability.     

Hydrogen production via steam reforming of ethylene glycol over Attapulgite supported nickel catalysts

Steam reforming of ethylene glycol was investigated over Ni-based catalysts supported on Attapulgite (ATP; originating from Jiangsu (JS), Anhui, and Gansu (GS) provinces in China). N₂ adsorption–desorption, XRD, FTIR, H₂-TPR, NH₃-TPD, SEM, and TEM-EDS measurements were performed to analyze the catalyst properties. The results revealed that Ni/ATP_GS had the largest particle size (17.9 nm) and the highest reductive degree (98.0%). Consequently, Ni/ATP_GS showed the highest ethylene glycol conversion (97.2%) during the first 4 h of reaction. However, this catalyst showed the lowest H₂ yield (71.2%), possibly owing to large Ni particle sizes as well as ample surface acidic sites and acidity, leading to a high selectivity toward CH₄ (20.8%) and C₂H₄ (2.2%). In contrast, Ni/ATP_JS presented the highest H₂ yield (89.8%) owing to it having the smallest Ni particle sizes and lowest amount of surface acidic sites. Additionally, this catalyst showed the highest stability over 8 h of reaction. An examination of the spent catalysts revealed that Ni/ATP_JS possessed excellent antisintering and coking properties.     

RuRh based catalysts for hydrogen production via methanol steam reforming in conventional and membrane reactors

Results of hydrogen production study in methanol steam reforming (MSR) process with the use of Ru_0.5–Rh_0.5 catalysts supported on different carbon materials: synthetic graphite-like material Sibunit, carbon black Ketjenblack EC600DJ, detonation nanodiamonds (DND) and ZrO₂-based material with fluorite structure, doped with ceria, have been described. The samples have been tested in conventional flow reactor and membrane (MR) reactor, containing Pd-based membranes with different composition, thickness and surface architecture. It has been shown that the catalytic activity of the composites depends on the support nature. The RuRh/DND catalyst exhibits the highest activity, whereas RuRh/Ce_0.1Zr_0.9O_2–δ is the most selective. The use of PdAg (23%) foil with the surface modified by palladium black showed great advantages comparing to the smooth dense membrane. The use of the MR with the PdAg membrane improves the MSR reaction and provides almost 50% increase in the hydrogen yield. The hydrogen produced with the use of the MR is ultra pure.     

Hydrogen production by steam reforming of ethanol over Co/CeO2 catalysts: Effect of cobalt content

The Co/CeO₂ catalysts obtained by co-precipitation method were used in the steam reforming of ethanol (SRE). The influence of cobalt active phase content (15–29 wt%), the reaction temperature (420–600 °C) and H₂O/EtOH molar ratio (12/1 and 6/1) were examined. The physicochemical characterization revealed that the cobalt content of the catalyst influences the metal-support interaction which results in catalyst performance in SRE process. The differences between catalytic properties of the Co/CeO₂ catalysts with different metal loading in SRE process decayed at 500 °C for H₂O/EtOH = 12/1. The best performance among the tested catalysts showed the 29Co/CeO₂ catalyst with the highest cobalt content, exhibiting the highest ethanol conversion, selectivity to two most desirable products and the lowest selectivity to by-products in comparison with catalysts containing smaller amount of metal. Its catalytic properties results probably from its unique physicochemical properties, i.e this catalyst contains large amount of cobalt but the metal crystallites are relatively small. Regardless cobalt content, an increase in the water-to-ethanol molar ratio in the feed increased the concentration of hydrogen an carbon dioxide and decreased formation of carbon monoxide, acetone, aldehyde and ethylene.     

Hydrogen production by steam reforming of dimethyl ether and CO-PrOx in a metal foam micro-reactor

A bi-function catalyst containing CuZnAlCr and HZSM-5 was used to generate hydrogen by stream reforming of dimethyl ether (SRD) in a metal foam micro-reactor and a fix-bed reactor. Dimethyl ether conversion of 99% and hydrogen yield of >95% was reached with HZSM-5/CuZnAlCr (mass ratio of 1:1) in the micro-reactor. A suitable balance between the dimethyl ether hydrolysis and methanol reforming steps requires the proper acidity and the metal sites. The CuZnAlCr/HZSM-5 properties, effect of CuZnAlCr to HZSM-5 mass ratio were investigated in the metal foam micro-reactor. Moreover, CO was removed from hydrogen-rich gas by preferential oxidation reaction (CO-PrOx) with PtFe/γ-Al₂O₃ catalyst in a similar metal foam micro-reactor follows the SRD stage. With the optimized O₂/CO ratio and reaction temperature, the CO concentration dropped to <10 ppm and hydrogen yield of ∼90% were achieved in the new-type SRD-COPrOx system. The SRD-COPrOx system provide a constant hydrogen production with CO concentration lower than 10 ppm during 20 h. The results indicate that metal foam micro-reactor has the great potential in the DME steam reforming to supply hydrogen for low-temperature fuel cells.     

Performance assessment and evaluation of catalytic membrane reactor for pure hydrogen production via steam reforming of methanol

The steam reforming of methanol was investigated in a catalytic Pd–Ag membrane reactor at different operating conditions on a commercial Cu/ZnO/Al₂O₃ catalyst. A comprehensive two-dimensional non-isothermal stationary mathematical model has been developed. The present model takes into account the main chemical reactions, heat and mass transfer phenomena in the membrane reactor with hydrogen permeation across the PdAg membrane in radial direction. Model validation revealed that the predicted results satisfy the experimental data reasonably well under the different operating conditions. Also the impact of different operating parameters including temperature, pressure, sweep ratio and steam ratio on the performance of reactor has been examined in terms of methanol conversion and hydrogen recovery. The modeling results have indicated the high performance of the membrane reactor which is related to continuous removal of hydrogen from retentate side through the membrane to shift the reaction equilibrium towards formation of hydrogen. The obtained results have confirmed that increasing the temperature improves the kinetic properties of the catalyst and increase in the membrane's H₂ permeance, which results in higher methanol conversion and hydrogen production. Also it is inferred that the hydrogen recovery is favored at higher temperature, pressure, sweep ratio and steam ratio. The model prediction revealed that at 573 K, 2 bar and sweep ratio of 1, the maximum hydrogen recovery improves from 64% to 100% with increasing the steam ratio from 1 to 4.     

Assessment of CO2 capture options from various points in steam methane reforming for hydrogen production

Steam methane reforming (SMR) is currently the main hydrogen production process in industry, but it has high emissions of CO₂, at almost 7 kg CO₂/kg H₂ on average, and is responsible for about 3% of global industrial sector CO₂ emissions. Here, the results are reported of an investigation of the effect of steam-to-carbon ratio (S/C) on CO₂ capture criteria from various locations in the process, i.e. synthesis gas stream (location 1), pressure swing adsorber (PSA) tail gas (location 2), and furnace flue gases (location 3). The CO₂ capture criteria considered in this study are CO₂ partial pressure, CO₂ concentration, and CO₂ mass ratio compared to the final exhaust stream, which is furnace flue gases. The CO₂ capture number (N_cc) is proposed as measure of capture favourability, defined as the product of the three above capture criteria. A weighting of unity is used for each criterion. The best S/C ratio, in terms of providing better capture option, is determined. CO₂ removal from synthesis gas after the shift unit is found to be the best location for CO₂ capture due to its high partial pressure of CO₂. However, furnace flue gases, containing almost 50% of the CO₂ in produced in the process, are of great significance environmentally. Consequently, the effects of oxygen enrichment of the furnace feed are investigated, and it is found that this measure improves the CO₂ capture conditions for lower S/C ratios. Consequently, for an S/C ratio of 2.5, CO₂ capture from a flue gas stream is competitive with two other locations provided higher weighting factors are considered for the full presence of CO₂ in the flue gases stream. Considering carbon removal from flue gases, the ratio of hydrogen production rate and N_cc increases with rising reformer temperature.     

A review of CO2 sorbents for promoting hydrogen production in the sorption-enhanced steam reforming process

Sorption-enhanced-steam-reforming (SESR) is a thermochemical conversion technology that produces a high-purity hydrogen stream by utilizing in-situ removal of CO₂ with a sorbent. In this paper, the advantages and disadvantages of CaO based sorbents, alkali-metal based sorbents (Na₂ZrO₃, Li₂ZrO₃ and Li₄SiO₄), hydrotalcite based sorbents, bifunctional materials and sorbents prepared from wastes are briefly discussed, and the techniques to improve the sorption properties of these CO₂ sorbents are summarized. In the process of hydrogen production by sorption-enhanced-steam-reforming, the selection of suitable high-temperature CO₂ sorbent is the key to produce high purity hydrogen. Furthermore, the hydrogen-production performance of the above-mentioned sorbents in the SESR process is investigated and summarized. Finally, a future perspective and some suggestions regarding these five types of sorbents are put forward.