Methanol steam reforming in a planar wash coated microreactor integrated with a micro-combustor

A numerical simulation of methanol steam reforming in a microreactor integrated with a methanol micro-combustor is presented. Typical Cu/ZnO/Al₂O₃ and Pt catalysts are considered for the steam reforming and combustor channels respectively. The channel widths are considered at 700 μm in the baseline case, and the reactor length is taken at 20 mm. Effects of Cu/ZnO catalyst thickness, gas hourly space velocities of both steam reforming and combustion channels, reactor geometry, separating substrate properties, as well as inlet composition of the steam reforming channel are investigated. Results indicate that increasing catalyst thickness will enhance hydrogen production by about 68% when the catalyst thickness is increased from 10 μm to 100 μm. Gas space velocity of the steam reforming channel shows an optimum value of 3000 h⁻¹ for hydrogen yield, and the optimum value for the space velocity of the combustor channel is calculated at 24,000 h⁻¹. Effects of inlet steam to carbon ratio on hydrogen yield, methanol conversion, and CO generation are also examined. In addition, effects of the separating substrate thickness and material are examined. Higher methanol conversion and hydrogen yield are obtained by choosing a thinner substrate, while no significant change is seen by changing the substrate material from steel to aluminum with considerably different thermal conductivities. The produced hydrogen from an assembly of such microreactor at optimal conditions will be sufficient to operate a low-power, portable fuel cell.     

Integrated methanol reforming and oxidation in wash-coated microreactors: A three-dimensional simulation

A microreactor consisting of two parallel channels is numerically simulated where methanol steam reforming takes place in one channel, and the required heat is supplied by methanol oxidation in the other channel. Effects of different parameters on methanol conversion, hydrogen yield and CO concentration are examined. Results from the parametric study are then used to propose conditions for high methanol conversion and hydrogen yield. A microreactor with enhanced output conditions is thus designed which is capable of producing a gas stream consisting of 74% hydrogen (dry). CO concentration in the generated synthesis gas stream is low enough to require only a PROX reactor for CO clean-up, eliminating the need for a bulky water–gas shift reactor. The produced hydrogen from an assembly of such microreactors can feed a low-power PEM fuel cell. A cluster of these microreactors would take a volume of about 91 cm³ to feed a typical 30-watt PEM fuel cell.     

Co-current and counter-current modes for methanol steam reforming membrane reactor

In this simulation study, methanol steam reforming reaction to produce synthesis gas has been studied in a membrane reactor when shell side and lumen side streams are in co-current mode or in counter-current mode. The simulation results for both co-current and counter-current modes are presented in terms of methanol conversion and molar fraction versus temperature, pressure, _H2O/_CH3OH${\mathrm{H}}_2\mathrm{O}/{\mathrm{CH}}_3\mathrm{OH}$ molar feed flow rate ratio and axial co-ordinate.     

Synthesis and characterization of non-noble nanocatalysts for hydrogen production in microreactors

Nanoscale Co and Ni catalysts in silica were synthesized using sol–gel method for hydrogen production from steam reforming of methanol (SRM) in silicon microreactors with 50 μm channels. Silica sol–gel support with porous structure gives specific surface area of 452.35 m² g⁻¹ for Ni/SiO₂ and 337.72 m² g⁻¹ for Co/SiO₂. TEM images show the particles size of Ni and Co catalysts to be <10 nm. The EDX results indicate Co and Ni loadings of 5–6 wt.% in silica which is lower than the intended loading of 12 wt.%. The DTA and XRD data suggest that 450 °C is an optimum temperature for catalyst calcination when most of the metal hydroxides are converted to metal oxides without significant particle aggregation to form larger crystallites. SRM reactions show 53% methanol conversion with 74% hydrogen selectivity at 5 μL min⁻¹ and 200 °C for Ni/SiO₂ catalyst, which is higher than that for Co/SiO₂. The activity of the metal catalysts decrease significantly after SRM reactions over 10 h, and it is consistent with the magnetization (VSM) results indicating that ∼90% of Co and ∼85% of Ni become non-ferromagnetic after 10 h.     

Numerical predictions of design and operating parameters of reformer on the fuel conversion and CO production for the steam reforming of methanol

SIMPLE-C algorithm and Arrhenius form of reaction model were employed to simulate the three-dimensional laminar flow field and the chemical reaction in a cylindrical methanol reformer under steam reforming. The effects of geometrical and thermo-fluid parameters on the CO and CO₂ productions as well as the heat and mass transfer in a cylindrical methanol reformer with a constant-volume catalyst bed will be observed in the present study. Low CO concentration in hydrogen-rich gas denotes a low load of CO removal in purifying processes. The results indicate that the smaller diameter-to-length ratio of chamber with a thicker catalyst bed enhances the methanol conversion and reduces the overall CO concentration in the cylindrical methanol reformer. This is because that a lower temperature distribution restrains the reverse water–gas-shift reaction to reduce the production of CO with a thicker catalyst bed.     

Methanol and ethanol steam reforming in membrane reactors: An experimental study

In this work a comparison between methanol steam reforming (MSR) reaction and ethanol steam reforming (ESR) reaction to produce hydrogen in membrane reactors (MRs) is discussed from an experimental point of view.     

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.     

Experiments on hydrogen production from methanol steam reforming in the microchannel reactor

The entire experiments were conducted for microchannel methanol steam reforming, by which, the selection of catalyst, the operating parameters and the configuration of microchannels were discussed thoroughly. It was found that the higher the Cu concentration is, the more the corresponding active surface area of Cu will be, thereby improving the catalytic activity. The Cu-to-Zn ratio in Cu/ZnO/Al₂O₃ catalyst should be set at 1:1. The impacts of reaction temperature, feed flow rate, mixture temperature, and H₂O-to-CH₃OH molar ratio on the methanol conversion rate were also revealed and discussed. Characteristics of micro-reactors with various microchannels, including that 20 mm and 50 mm in length, as well as non-parallel microchannels, were investigated. It was found that the increase of microchannel length can improve the methanol conversion rate significantly. Besides, non-parallel microchannels help to maintain flow and temperature distribution uniformity, which can improve the performance of micro-reactor. In the present experiments, the presence of CO was under the condition that the methanol conversion rate was above 70%.     

A monolith CuNiFe/γ-Al2O3/Al catalyst for steam reforming of dimethyl ether and applied in a microreactor

Structured CuNi/γ-Al₂O₃/Al catalyst exhibited a good stability in steam reforming of dimethyl ether (DME SR) system, but there was a high CO concentration in outlet gas (about 25%). For the problem, a series of CuNiFe/γ-Al₂O₃/Al catalysts with different Fe content were prepared through impregnation method. It is found that the CO concentration obviously decreased after the addition of Fe. When the loading amount of Fe was 12.5 wt%, the catalyst presented the best performance: the conversion of DME reached 100% and the H₂ yield was over 0.9 in both the microreactor and fixed-bed reactor. Furthermore, cross-flow channels and parallel-flow channels were built respectively by mesh-type catalyst and plate-type catalyst in the microreactor. The gas/solid mass transfer limitations in both flow channels were investigated by Damköhler number (Da). The results showed that the Da values of cross flow were always <0.01, while the values of parallel flow were >0.01. It indicated that the diffusion over mesh-type catalyst was less influenced by temperature and reactor height, making it a more appropriate choice for the microreactor.     

Biogas reforming for hydrogen enrichment by ceria decorated over nickel catalyst supported on titania and alumina

Catalytic dry reforming of biogas for hydrogen enrichment was studied over cerium oxide promoted nickel catalysts supported on titanium dioxide and aluminium oxide. The catalysts were prepared by wet impregnation method and characterized by H₂-TPR, XRD, BET and FESEM techniques. Their catalytic performance in the biogas dry reforming reaction was studied at temperature ranges from 650 to 850 °C, with a CH₄/CO₂ ratio of 1.5:1. The H₂-TPR results revealed that 11 wt % Ni impregnation on TiO₂ support makes the catalyst with strong metal-support interaction which moderates the metal sintering. Also, the addition of CeO₂ effectively improved the CH₄ and CO₂ conversions as well as H₂ enrichment. At 850 °C, 11 wt % Ni/TiO₂ catalyst leads to 70.5% CH₄ conversion with 32.0% H₂ enrichment, whereas, Ni_0·11/Ce_0.20 (Al₂O₃TiO₂) yielded high CH₄ conversion (84.9%) with 40.6% of H₂ enrichment. No significant change in the activity of the catalyst was observed with 8.8 wt % of carbon deposited on the Ni_0·11/Ce_0.20 (Al₂O₃TiO₂) catalyst, after 7 h of continuous reforming. Moreover, under combined (dry and oxidative) reforming of biogas, the stoichiometric H₂/CO ratio (1.2) was observed at 0.47 O₂/CH₄ ratios with negligible carbon deposition. Thus, Ni_0·11/Ce_0.20 (Al₂O₃TiO₂) catalyst exhibited better activity and selectivity with high catalyst stability at 850 °C.     

Autothermal generation of hydrogen from ethanol in a microreactor

A two-side platelet microreactor was designed, modeled, and tested for the generation of hydrogen from ethanol under autothermal regime. The microchannels of one side of the platelet microreactor were coated with Co/ZnO catalyst for conducting the ethanol steam reforming reaction for producing hydrogen at low temperature, whereas the microchannels of the other side of the platelet were coated with _CuMnOx${\mathrm{CuMnO}}_x$ catalyst for the complete oxidation of ethanol. The heat released during ethanol combustion was used for maintaining the heat demand for the endothermic steam reforming side of the microreactor. Several preparation methods were used and compared for the deposition of catalysts in the microchannels in order to guarantee homogeneous deposition and stability. An amount of 3.67 mol of hydrogen per mol of total ethanol consumed in both sides of the microreactor was obtained at 733 K. The overall efficiency of the microreactor was 71%.     

Methanol steam reforming in microreactor with constructal tree-shaped network

The construcal tree-shaped network is introduced into the design of a methanol steam microreactor in the context of optimization of the flow configuration. A three-dimensional model for methanol steam reaction in this designed microreactor is developed and numerically analyzed. The methanol conversion, CO concentration in the product and the total pressure drop of the gases in the microreactor with constructal tree-shaped network are evaluated and compared with those in the serpentine reactor. It is found that the reaction of methanol steam reforming is enhanced in the constructal tree-shaped microreactor, since the tree-shaped reactor configuration, which acts an optimizer for the reactant distribution, provides a reaction space with larger surface-to-volume ratio and the reduction of reactant velocities in the branches. Compared with the serpentine microreactor, the constructal reactor possesses a higher methanol conversion rate accompanied with a higher CO concentration. The conversion rate of the constructal microreactor is more than 10% over that of serpentine reactor. More particularly, the reduction of flow distance makes the constructal microreactor still possess almost the same pressure drop as the corresponding serpentine reactor, despite that the bifurcations induce extra local pressure loss, and the reduction of channel size in branches also causes pressure losses.     

Effects of synthesis methods on performance of CuZn/MCM-41 catalysts in methanol steam reforming

CuZn-based catalysts are active in production of hydrogen by methanol steam reforming. However, there is a need to have further insight on their physico-chemical properties to improve selectivity to hydrogen. Therefore, a series of CuZn/MCM-41 catalysts was synthesized by four different routes; one pot hydrothermal synthesis (OPMCM), co-impregnation (COMCM), serial impregnation (SRMCM) and copper impregnated on Zn-MCM-41 (ZNMCM). Samples of catalysts were characterized by X-ray diffraction (XRD), transmission electron microscopy (TEM), scanning electron microscopy (SEM) coupled with energy dispersive X-ray spectroscopy (EDS), inductively coupled plasma (ICP) emission spectrometry, Fourier transform infrared (FTIR) spectroscopy, thermogravimetric analysis (TGA) and X-ray photoelectron spectroscopy (XPS). XRD revealed disruption in the ordered pore network typical in MCM-41 for all catalysts synthesized and also showed that the one pot synthesis catalyst had wide spread dispersion of Cu and Zn. SEM micrographs captured irregularly shaped particles of different sizes. While XPS showed that different Cu and Zn species were formed within the catalyst matrix. XPS also confirmed that there was wide spread dispersion and interaction of Cu and Zn with MCM-41 matrix in the OPMCM catalyst. COMCM and OPMCM demonstrated the highest activity with 88 and 65% methanol conversion with corresponding H₂ selectivity of 91 and 86% respectively. They are better than SRMCM and ZNMCM which had average H₂ selectivity of 19% and 31% respectively. CO selectivity was less than 1.8% for the COMCM and OPMCM catalysts. While SRMCM and ZNMCM had CO selectivity's as high as 8.9% and 7.2% respectively. The data generated shows that catalytic activity is largely affected by the nature of Cu species within the catalyst matrix.     

Biogas steam and oxidative reforming processes for synthesis gas and hydrogen production in conventional and microreactor reaction systems

In this work, a renewable source, biogas, was used for synthesis gas and hydrogen generation by steam reforming (SR) or oxidative reforming (OR) processes. Several Ni-based catalysts and a bimetallic Rh–Ni catalyst supported on magnesia or alumina modified with oxides like CeO₂ and ZrO₂ were used. For all the experiments, a synthetic biogas which consisted of 60% CH₄ and 40% CO₂ (vol.) was fed and tested in a fixed bed reactor system and in a microreactor reaction system at 1073 K and atmospheric pressure. The catalysts which achieved high activity and stability were impregnated in a microreactor to explore the viability of process intensification. For the SR process different steam to carbon ratios, S/C, varied from 1.0 to 3.0 were used. In the case of OR process the O₂/CH₄ ratio was varied from 0.125 to 0.50. Comparing conventional and microreactor reaction systems, one order of magnitude higher TOF and productivity values were obtained in the microreactors, while for all the tested catalysts a similar activity results were achieved. Physicochemical characterization of catalysts samples by ICP-AES, N₂ physisorption, H₂ chemisorption, TPR, SEM, XPS and XRD showed differences in chemical state, metal–support interactions, average crystallite sizes and redox properties of nickel and rhodium metal particles, indicating the importance of the morphological and surface properties of metal phases in driving the reforming activity.     

A novel thermally autonomous methanol steam reforming microreactor using SiC honeycomb ceramic as catalyst support for hydrogen production

Methanol steam reforming (MSR) is an attractive option for in-situ hydrogen production and to supply for transportation and industrial applications. This paper presents a novel thermally autonomous MSR microreactor that uses silicon carbide (SiC) honeycomb ceramic as a catalyst support to enhance energy conversion efficiency and hydrogen production. The structural design and working principle of the MSR microreactor are described along with the development of a 3D numerical model to study the heat transfer and fluid flow characteristics. The simulation results indicate that the proposed microreactor has a significantly low drop in pressure and more uniform temperature distribution in the SiC ceramic support. Further, the microreactor was developed and an experimental setup was conducted to test its hydrogen production performance. The experimental results show that the developed microreactor can be operated as thermally autonomous to reach its target working temperature within 9 min. The maximum energy efficiency of the microreactor is 67.85% and a hydrogen production of 316.37 ml/min can be achieved at an inlet methanol flow rate of 360 μl/min. The obtained results demonstrate that SiC honeycomb ceramic with high thermal conductivity can serve as an effective catalyst support for the development of MSR microreactors for high volume and efficient hydrogen production.     

One-step growth of CuO/ZnO/CeO2/ZrO2 nanoflowers catalyst by hydrothermal method on Al2O3 support for methanol steam reforming in a microreactor

CuO/ZnO/CeO₂/ZrO₂ nanoflowers catalyst was grown on an Al₂O₃ foam ceramic by a one-step hydrothermal process, while a naked Al₂O₃ foam ceramic and an Al₂O₃ foam ceramic grown with ZnO nanorods that directly impregnated into the catalyst precursor solution were also fabricated simultaneously. The morphology, composition, redox property and specific surface area of catalysts on the three ceramics were investigated in detail. The catalyst-loaded ceramics were used as catalyst supports in a microreactor to study the catalytic performance for methanol steam reforming. Results showed that the microreactor with Al₂O₃ support grown with nanoflowers catalyst achieved 99.8% methanol conversion rate, 0.16 mol/h H₂ flow rate at 310 °C, and an inlet methanol flow rate of 0.048 mol/h. Moreover, the microreactor exhibited 92% methanol conversion rate after 30 h continuous reaction.     

A million-channel reformer on a fingertip: Moving down the scale in hydrogen production

The present contribution reports the design, manufacture and experimental proof of concept of an ethanol micro-reformer for portable-fuel cell feeding. Through photo-assisted electrochemical etching, a silicon micromonolithic substrate with perfectly parallel cylindrical channels of 3.3 μm diameter was achieved (density of channels of ca. 4 × 10⁴ channels mm⁻²). The channel walls were coated with a cobalt-based catalyst. The resultant functionalized micromonoliths were implemented in a stainless steel microreactor including feed evaporation facilities and electrical heating. The unit was successfully tested for ethanol steam reforming under non-diluted feed conditions at 773 K, achieving high hydrogen specific production rates, high ethanol conversions (>80%) and adequate selectivity profiles, with H₂:CO₂ molar ratios of ∼3 and low CO outlet concentrations. A performance comparison was performed with two other reforming substrates with the same catalyst formulation, namely, a conventional cordierite monolith and a conventional stainless steel microreactor. Results show for the Si-micromonolithic reactor a remarkable improvement of the specific hydrogen production rate (per unit reactor volume and feed flowrate), operating at considerably reduced residence times, due to the increase in contact area per unit volume.