Hysteresis loops of methane catalytic partial oxidation for hydrogen production under the effects of varied Reynolds number and Damköhler number

Hysteresis loops of catalytic partial oxidation of methane (CPOM) for hydrogen production under the effects of varied Reynolds number and Damköhler number are investigated numerically in this study. The physical phenomena are predicted using the indirect mechanism, which consists of the total oxidation (or combustion), steam reforming and CO₂ reforming of methane in a catalyst bed. Numerical results reveal that, when the Damköhler number is relatively low, a hysteresis loop of CPOM from varying Reynolds number develops. Increasing the Damköhler number leads to the loop shifting toward the regime of high Reynolds number. However, once the Damköhler number is large to a certain extent, the chemical reactions are always exhibited for the Reynolds number less than 2000. A closed loop is thus not observed. Alternatively, for a given Reynolds number, an ignited Damköhler number and an extinguished Damköhler number can be obtained. Accordingly, three different regions in the plot of Damköhler number versus Reynolds number are identified. Physically, when the role played by Damköhler number on CPOM is much more important than by the Reynolds number (Region I), the thermal effect governs the chemical reactions. In contrast, if the Reynolds number plays a key role in determining the CPOM (Region III), the chemically frozen flow prevails over the catalyst bed. When the residence times of the total oxidation and convection in the catalyst bed are in an equivalent state (Region II), CPOM is characterized by a dual-solution, rendering the hysteresis loops. From the distributions of ignited and extinguished Damköhler numbers, the catalytic reactor and operation of partial oxidation of methane and other fuels can be designed accordingly.     

Hydrogen production by coupled catalytic partial oxidation and steam methane reforming at elevated pressure and temperature

Hydrogen production by coupled catalytic partial oxidation (CPO) and steam methane reforming of methane (OSMR) at industrial conditions (high temperatures and pressures) have been studied over supported 1 wt.% NiB catalysts. Mixture of air/CH₄/H₂O was applied as the feed. The effects of O₂:CH₄ ratio, H₂O:CH₄ ratio and the gas hourly space velocity (GHSV) on oxy-steam reforming (OSRM) were also studied. Results indicate that CH₄ conversion increases significantly with increasing O₂:CH₄ or H₂O:CH₄ ratio. However, the hydrogen mole fraction goes through a maximum, depending on reaction conditions, e.g., pressure, temperature and the feed gases ratios. Carbon deposition on the catalysts has been greatly decreased after steam addition. The supported 1 wt.% NiB catalysts exhibit high stability with 85% methane conversion at 15 bar and 800 °C during 70 h time-on-stream reaction (CH₄:O₂:H₂O:N₂ = 1:0.5:1:1.887). The thermal efficiency was increased from 35.8% by CPO (without steam) to 55.6%. The presented data would be useful references for further design of enlarged scale hydrogen production system.     

Enhancement effect of heat recovery on hydrogen production from catalytic partial oxidation of methane

The effect of heat recovery on hydrogen production from catalytic partial oxidation of methane (CPOM) and its reaction characteristics in a reactor are investigated using numerical simulations. The reactor is featured by a Swiss-roll structure in which a rhodium (Rh) catalyst bed is embedded at the center of the reactor. By recovering the waste heat from the product gas to preheat the reactants, it is found that the combustion, steam reforming and dry reforming of methane in the catalyst bed are enhanced to a great extent. As a result, the methane conversion and hydrogen yield are improved more than 10%. Considering the operation conditions, a high performance of hydrogen production from CPOM can be achieved if the number of turns in the reactor is increased or the gas hourly space velocity (GHSV) of the reactants in the catalyst bed is lower. However, with the condition of heat recovery, the flow direction of the reactants in the reactor almost plays no part in affecting the performance of CPOM. In summary, the predictions reveal that the reactor with a Swiss-roll structure can be applied for implementing CPOM with high yield of hydrogen.     

Transient reaction and exergy analysis of catalytic partial oxidation of methane in a Swiss-roll reactor for hydrogen production

Catalytic partial oxidation of methane (CPOM) is a promising method for hydrogen production with autothermal reaction. To figure out the unsteady reaction characteristics of CPOM in a Swiss-roll reactor along with heat recirculation, a numerical method is employed to simulate the transient reaction dynamics, with emphasis on energy recovery using exergy analysis. Three different gas hourly space velocities (GHSVs) of 5000, 10,000 and 50,000 h⁻¹ with the condition of atomic O/C ratio of 1 are considered. The predictions indicate that increasing GHSV substantially shortens the transient period of chemical reactions; however, it also reduces the methane conversion, as results of more reactants sent into the reactor and shorter residence time of the reactants in the catalyst bed. Within the investigated range of GHSV, the methane conversion with energy recovery at the steady state is larger than 80%, much higher than the reaction without heat recovery. The selectivities of H₂ and CO in the product gas are always larger than 90%. The exergy recovery is in the range of 66–80%, implying that over two-third useful work contained in the product gas can be reused to preheat the reactants in the reactor, thereby enhancing the performance of CPOM.     

Enhancement of heat recirculation on the hysteresis effect of catalytic partial oxidation of methane

The hysteresis characteristics of catalytic partial oxidation of methane (CPOM) in a Swiss-roll reactor are predicted numerically by varying Damköhler number. Particular attention is paid to the influences of heat recirculation, gas hourly space velocity (GHSV), and atomic O/C ratio on the hysteresis loop and performance of CPOM. The reactions of methane combustion, steam reforming, and CO₂ or dry reforming are simultaneously considered. The results reveal that preheating reactants through excess enthalpy recovery is conducive to the ignition of CPOM and extending its extinction limit, so the ignition and extinction Damköhler numbers are lowered. The analysis also suggests that steam reforming is more sensitive to the heat recovery than methane combustion and dry reforming. An increase in GHSV reduces the residence time of reactants in the catalyst bed, thereby enlarging the ignition and extinction Damköhler numbers of CPOM. A higher O/C ratio facilitates the ignition of CPOM, stemming from more oxygen supplied, but the ratio should be controlled below 1.2. From the hysteresis phenomena, hydrogen can be produced from methane at a lower Damköhler number to save more energy for performing CPOM.     

Experimental and numerical study of syngas production during premixed and ultra-rich partial oxidation of methane in a porous reactor

The synthesis gas (syngas) production from the ultra-rich methane/oxygen mixtures via the thermal partial oxidation in an inert porous reactor was investigated numerically and experimentally. Thermodynamic analysis was firstly conducted based on Gibbs free energy minimization method to find the possible optimum routes of operation. Then, the experiments were performed on the constructed test-rig with a non-catalytic porous based reformer. The flame is stabilized within zirconia (ZrO₂) sponge, which has shown very high mechanical strength and thermal resistance. The main influencing parameters such as the equivalence ratio and thermal load have been investigated during different experiments. For this purpose, the reactor axial temperature profile and product compositions were determined experimentally. The obtained results reveal that the heat loss abatement; approaching to the adiabatic condition could effectively improve the amounts of syngas (H₂+CO) production. The maximum syngas production was obtained 69.5% of the exhaust gas at the equivalence ratio of 2.5 and thermal load of 8 kW. Moreover, the H₂/CO ratio was reported above 1.5, which can be suitable for feeding into other chemical processes. Finally, numerical simulation of the process was performed using the premixed and reactor network models. The contribution of heat loss from the reactor was also considered in the model due to its pivotal role observed in the experimental work. The average relative error of the reactor network model with respect to syngas generated from the reformer was found to be 6.72%. Therefore, the predictions obtained from this model are in fairly good agreement with the experimental data.     

Production of synthesis gas by partial oxidation and steam reforming of biomass pyrolysis oils

As the lowest cost biomass-derived liquids, pyrolysis oils (also called bio-oils) represent a promising vector for biomass to fuels conversion. However, bio-oils require upgrading to interface with existing infrastructure. A potential pathway for producing fuels from pyrolysis oils proceeds through gasification, the conversion to synthesis gas. In this work, the conversion of bio-oils to syngas via catalytic partial oxidation over Rh–Ce is evaluated using two reactor configurations. In one instance, pyrolysis oils are oxidized in excess steam in a freeboard and passed over the catalyst in a second zone. In the second instance, bio-oils are introduced directly to the catalyst. Coke formation is avoided in both configurations due to rapid oxidation. H₂ and CO can be produced autothermally over Rh–Ce catalysts with millisecond contact times. Co-processing of bio-oil with methane or methanol improved the reactor operation stability.     

Entropy generation from hydrogen production of catalytic partial oxidation of methane with excess enthalpy recovery

Catalytic partial oxidation of methane (CPOM) is an important route for producing hydrogen and it is featured by autothermal reaction. To recognize the reaction characteristics of CPOM, H₂ production and entropy generation from CPOM in Swiss-roll reactors are studied numerically. The considered parameters affecting the performance of CPOM include the excess enthalpy recovery, gas hourly space velocity (GHSV), number of turns and atomic O/C ratio. The impact of chemical reactions, heat transfer and friction on entropy generation is also analyzed. The results indicate that preheating reactants through waste heat recovery as well as increasing GHSV or number of turns is conducive to enhancing H₂ yield, whereas the maximum H₂ yield develops at O/C = 1.2. A higher H₂ yield is always accompanied by a higher value of entropy generation, and chemical reactions are the main source of entropy generation, especially from steam methane reforming. In contrast, viscous dissipation almost plays no part on entropy generation, compared to heat transfer and chemical reactions. From the analysis of entropy generation, detailed mechanisms of H₂ production from CPOM can be figured out.     

Hydrogen production from methane under the interaction of catalytic partial oxidation,water gas shift reaction and heat recovery

Hydrogen production from the combination of catalytic partial oxidation of methane (CPOM) and water gas shift reaction (WGSR), viz. the two-stage reaction, in a Swiss-roll reactor is investigated numerically. Particular emphasis is placed on the interaction among the reaction of CPOM, the cooling effect due to steam injection and the excess enthalpy recovery with heat recirculation. A rhodium (Rh) catalyst bed sitting at the center of the reactor is used to trigger CPOM, and two different WGSRs, with the aids of a high-temperature (Fe–Cr-based) shift catalyst and a low-temperature (Cu–Zn-based) shift catalyst, are excited. Two important parameters, including the oxygen/methane (O/C) ratio and the steam/methane (S/C) ratio, affecting the efficiencies of methane conversion and hydrogen production are taken into account. The predictions indicate that the O/C ratio of 1.2 provides the best production of H₂ from the two-stage reaction. For a fixed O/C ratio, the H₂ yield is relatively low at a lower S/C ratio, stemming from the lower performance of WGSR, even though the cooling effect of steam is lower. On the contrary, the cooling effect becomes pronounced as the S/C ratio is high to a certain extent and the lessened CPOM leads to a lower H₂ yield. As a result, with the condition of gas hourly space velocity (GHSV) of 10,000 h⁻¹, the optimal operation for hydrogen production in the Swiss-roll reactor is suggested at O/C = 1.2 and S/C = 4–6.     

Study of partial oxidation reforming of methane to syngas over self-sustained electrochemical promotion catalyst

A self-sustained electrochemical promotion (SSEP) catalyst is synthesized for partial oxidation reforming (POXR) of CH₄ to produce syngas (H₂ and CO) at a relatively low temperature ranging from 350 to 650 °C. The SSEP catalyst is comprised of 4 components: microscopic Ni/Cu/CeO₂ anode, La_0.9Sr_0.1MnO₃ cathode, copper as electron conductor, and yttria-stabilized-zirconia as oxygen ion conductor, which form microscopic electrochemical cells to enable the self-sustained electrochemical promotion for the POXR process. The SSEP catalyst exhibited much better catalytic performance in POXR of CH₄ than a Ni–Cu–CeO₂ catalyst and a commercial Pt–CeO₂ catalyst. The CH₄ conversion over the SSEP catalyst is 29.4% at 350 °C and reaches 100% at 550 °C and the maximum selectivity to H₂ is on the level of 90% at 450–650 °C under a GHSV of 42,000 h⁻¹. The mechanism of the SSEP is discussed.     

Catalytic partial oxidation of methane over nanosized Rh supported on Fecralloy foams

Structured catalysts for the partial oxidation of methane were prepared by supporting Rh nanoparticles onto Fecralloy foams at relatively low precious metal loadings. The investigation was focused mainly on an innovative and straightforward preparation procedure consisting in the direct cathodic electrodeposition of Rh onto foam samples. For the sake of comparison, other Rh-based catalysts were prepared with a more traditional approach, by using the same foams and an AlPO₄ washcoat layer. The catalysts were characterized by SEM-EDS, XRD and cyclic voltammetry, to assess the Rh surface area, and tested in the CPO of methane to syngas under self-sustained high temperature conditions at short-contact-time. During prolonged CPO tests the performance of electrochemically prepared catalysts underwent a progressive decline, as compared to stable operation of AlPO₄ washcoated catalysts, which was mainly ascribed to sintering of Rh nanoparticles, negatively affecting the activity for methane steam reforming.     

Performance and stability of La0.5Sr0.5CoO3−δ perovskite as catalyst precursor for syngas production by partial oxidation of methane

The aim of this work was to investigate the performance and stability of the perovskite La_0.5Sr_0.5CoO_3−δ, as a potential catalyst precursor, for the synthesis gas production by partial oxidation of methane. For this purpose, the catalytic activity of La_0.5Sr_0.5CoO_3−δ was studied as a function of the temperature, flow rate and feed composition. In addition, its stability with the time-on-stream and redox cycles was also explored. Before and after testing, the catalyst precursor was characterized by X-ray diffraction, SEM-EDX and specific surface area (BET). The results evidenced a remarkable catalytic activity due to the stability of the cobalt, which is in a highly disperse state, in its reduced state. The CH₄ conversion and the CO and H₂ selectivities were enhanced with the increase of redox cycles. Finally, the precursor was totally regenerated to the initial perovskite structure under a specific thermal treatment.     

Combined dry reforming and partial oxidation of methane to synthesis gas on noble metal catalysts

In this paper CO₂ reforming of methane combined with partial oxidation of methane to syngas over noble metal catalysts (Rh, Ru, Pt, Pd, Ir) supported on alumina-stabilized magnesia has been studied. The catalysts were characterized by using BET, XRD, SEM, TEM, TPR, TPH and H₂S chemisorption techniques. The H₂S chemisorption analysis showed an active metal crystallite size in the range of 1.8-4.24 nm for the prepared catalysts. The obtained results revealed that the Rh and Ru catalysts showed the highest activity in combined reforming and both the dry reforming and partial oxidation of methane. The obtained results also showed a high catalytic stability without any decrease in methane conversion up to 50 h of reaction. In addition, the H₂/CO ratio was around 2 and 0.7 over different catalysts for catalytic partial oxidation and dry reforming, respectively.     

Effect of ruthenium addition on molybdenum catalysts for syngas production via catalytic partial oxidation of methane in a monolithic reactor

Hydrogen is mainly produced from hydrocarbon resources. Natural gas, mostly composed of methane, is widely used for hydrogen production. As a valuable feedstock for ‘Fischer–Tropsch’ (FT) process and ‘Gas to Liquids’ (GTL) technology, syngas production from catalytic partial oxidation of methane (CPOM) is gaining prominence especially owing to its more desirable H₂/CO ratio; relatively less energy consumption, and lower investment, compared to steam reforming processes (SMR), the leading technology.In the present study, effect of ruthenium (Ru) addition on molybdenum (Mo) catalysts for syngas production from methane (CH₄) via partial oxidation in a monolithic reactor was investigated. Mo based catalysts supported on Nickel (Ni) and Cobalt (Co) metal oxides and Ni-Co bimetallic oxides and their Ru added versions were developed, characterized, and tested for performance in a monolithic type reactor system. Catalyst activity was investigated in terms of H₂ and CO selectivity, CH₄ conversion; and CO₂ emission and it is concluded that addition of Ru over the structure led to increase in catalytic activity and reduction in carbon deposition over the catalyst surface.     

甲烷快速部分氧化重整试验研究

采用常规浸渍法制备了Rh/α-Al2O3催化剂,建立了甲烷快速部分氧化重整试验体系。通过控制变量法,考察了甲烷快速部分氧化重整反应中反应条件参数(CH4/O2、反应气体预混合温度、空速)变化对反应物的转化率、反应产物及分布的影响。试验结果表明,在试验条件下,CH4的转化率始终大于85%,O2转化率接近100%,CO的选择性为85%左右,H2的选择性为40%～60%。反应过程大致为催化剂入口处的部分氧化反应和下游的水蒸气重整,大部分的CO由部分氧化产生,而H2的产生受水蒸气重整反应的影响较大;随着反应温度的上升,CH4的转化率上升,CO,H2的选择性也上升;随着空速的增大,H2的选择性减小,表明甲烷催化部分氧化反应是一个受传质控制的反应。     

Effect of sulphur during the catalytic partial oxidation of ethane over Rh and Pt honeycomb catalysts

The impact of sulphur addition (2–58 ppm) during the catalytic partial oxidation (CPO) of ethane was investigated on Rh- and Pt-based honeycomb catalysts tested under self-sustained high temperature conditions. Both steady state and transient operation of the CPO reactor were investigated particularly with regards to poisoning/regeneration cycles. A detailed analysis of products distribution in the effluent and a heat balance of the CPO reactor demonstrates that sulphur reversibly adsorbed on Rh selectively inhibits the ethane hydrogenolysis and, to a lower extent, steam reforming reaction. A further, simultaneous adverse effect of S on the kinetics of the reverse water gas shift reaction on Rh catalyst operating at temperatures < 750 °C can cause an unexpected increase in the H₂ yield above its equilibrium value for low concentrations of the poison. Pt catalyst is less active for those reactions but in turn is more S-tolerant.     

Role of the composition and preparation method in the activity of hydrotalcite-derived Ru catalysts in the catalytic partial oxidation of methane

Hydrotalcite-derived Ru catalysts were tested in the catalytic partial oxidation of CH₄ to produce syngas. The effect of Ru content, oxidic matrix composition, and preparation procedure on chemical–physical properties and performances of catalysts was studied. Bulk catalysts (0.25 and 0.50 wt.% Ru) were obtained via Ru/Mg/Al hydrotalcite-type (HT) precursors with carbonates or silicates as interlayer anions. A supported catalyst was prepared by impregnation on a calcined Mg/Al–CO₃ HT. Ru/γ-Al₂O₃ was evaluated for comparison. Both the Ru dispersion and the interaction with the support decreased as the Ru loading increased and when silicates were present due to RuO₂ segregation. Regardless of the Ru loading, carbonate-derived catalysts performed better than those containing silicates. The increased Ru loading improved the initial activity, but deactivation occurred after high temperature tests. Stability tests for shorter contact times over a 0.25 wt.% bulk sample obtained from Ru/Mg/Al HT with carbonates showed a tendency to deactivate at 750 °C.     

Thermodynamic analysis of hydrogen production from methane via autothermal reforming and partial oxidation followed by water gas shift reaction

Reaction characteristics of hydrogen production from a one-stage reaction and a two-stage reaction are studied and compared with each other in the present study, by means of thermodynamic analyses. In the one-stage reaction, the autothermal reforming (ATR) of methane is considered. In the two-stage reaction, it is featured by the partial oxidation of methane (POM) followed by a water gas shift reaction (WGSR) where the temperatures of POM and WGSR are individually controlled. The results indicate that the reaction temperature of ATR plays an important role in determining H₂ yield. Meanwhile, the conditions of higher steam/methane (S/C) ratio and lower oxygen/methane (O/C) ratio in association with a higher reaction temperature have a trend to increase H₂ yield. When O/C ≤ 0.125, the coking behavior may be exhibited. In regard to the two-stage reaction, it is found that the methane conversion is always high in POM, regardless of what the reaction temperature is. When the O/C ratio is smaller than 0.5, H₂ is generated from the partial oxidation and thermal decomposition of methane, causing solid carbon deposition. Following the performance of WGSR, it suggests that the H₂ yield of the two-stage reaction is significantly affected by the reaction temperature of WGSR. This reflects that the temperature of WGSR is the key factor in producing H₂. When methane, oxygen and steam are in the stoichiometric ratio (i.e. 1:0.5:1), the maximum H₂ yield from ATR is 2.25 which occurs at 800 °C. In contrast, the maximum H₂ yield of the two-stage reaction is 2.89 with the WGSR temperature of 200 °C. Accordingly, it reveals that the two-stage reaction is a recommended fuel processing method for hydrogen production because of its higher H₂ yield and flexible operation.     

Simulation of a fuel reforming system based on catalytic partial oxidation

Catalytic partial oxidation (CPO) has potential for producing hydrogen that can be fed to a fuel cell for portable power generation. In order to be used for this purpose, catalytic partial oxidation must be combined with other processes, such as water-gas shift and preferential oxidation, to produce hydrogen with minimal carbon monoxide. This paper evaluates the use of catalytic partial oxidation in an integrated system for conversion of a military logistic fuel, JP-8, to high-purity hydrogen. A fuel processing system using CPO as the first processing step is simulated to understand the trade-offs involved in using CPO. The effects of water flow rate, CPO reactor temperature, carbon to oxygen ratio in the CPO reactor, temperature of preferential oxidation, oxygen to carbon ratio in the preferential oxidation reactor, and temperature for the water-gas shift reaction are evaluated. The possibility of recycling water from the fuel cell for use in fuel processing is evaluated. Finally, heat integration options are explored. A process efficiency, defined as the ratio of the lower heating value of hydrogen to that of JP-8, of around 53% is possible with a carbon to oxygen ratio of 0.7. Higher efficiencies are possible (up to 71%) when higher C/O ratios are used, provided that olefin production can be minimized in the CPO reactor.     

Synthesis of NiO/MgO/ZrO2 catalyst for syngas production from partial oxidation and dry reforming of biogas

This work focuses on a facile NiO/MgO/ZrO₂ synthesis protocol for syngas production via partial oxidation and dry reforming of biogas. Herein, performance of the developed catalysts with different amounts of MgO (0–40 %wt. of support) and NiO (10–50 %wt.) on %CH₄ conversion, %CO₂ conversion, H₂/CO ratio, and carbon formation are studied. The results reveal the presence of monoclinic ZrO₂ and tetragonal ZrO₂ phases with 50%NiO/ZrO₂ catalyst synthesized by surface modification technique using carbon derived from urea. Addition of MgO in the catalyst shows ability to stabilize tetragonal ZrO₂ phase as well as enhance basic surface of the catalyst. These properties render the adsorption of CO₂ molecules on the surface, which subsequently are reduced by carbon, leading to CO production. Appropriated amount of NiO and MgO, which is 30 %wt. NiO and 20 %wt. MgO (relative to ZrO₂) can produce syngas having quality (H₂/CO molar ratio) of ca. 2.