Interactive heat transfer characteristics of 5 kW class shell-and-tube methane steam reformer with intermediate temperature heat source

A 5 kW class shell and tube methane steam reformer (MSR) with intermediate temperature heat source was evaluated to find a correlation between the methane conversion and heat transfer performance. First, performance evaluation of MSR1 was conducted by varying experimental conditions such as reformer reactant flow rate, steam to carbon ratio (SCR), inlet temperature of reforming zone, and inlet temperature of heat source. Sensitivity study of overall heat transfer coefficient was also carried out to find the major parameter affecting the heat transfer. Next, the heat transfer performance and methane conversion rate of MSR1 and 2 were compared. Both reformers have the same gas hourly space velocity (GHSV) in the form of shell and tube heat exchangers, but are designed to compare the heat transfer characteristics of the reformer by designing with the different heat transfer areas. The results show that the main factors affecting the performance of the reformer are load, heat source inlet temperature, and heat transfer area.     

Performance improvement of methanol steam reforming system with auxiliary heat recovery units

The thermal energy of a methanol steam reforming system is balanced with heat-up by a methanol burner, heat absorption by an evaporator, and an endothermic reforming reactor. As the thermal energy of a methanol steam reformer is delicately controlled, its thermal efficiency is significantly improved. In this study, three different system configurations are compared, namely, (1) a reference methanol steam reformer with an external evaporator, (2) a methanol steam reformer with an internal evaporator and type-1 auxiliary heat recovery unit (AHRU) with a heat source gas, and (3) a methanol steam reformer with an internal evaporator and type-2 AHRU with a heat source gas and reformed gas. These three configurations are analyzed, and the two heat recovery units are investigated. Results show that the internally evaporated methanol steam reformer efficiently converts the methanol to a hydrogen-rich mixture as exit gases are utilized to heat up the inlet methanol/water mixture.     

Numerical study on solar-driven methanol steam reforming reactor with multiple phase change materials

The multi-stage phase change material (PCM) fillings were proposed in the methanol steam reforming tube reactor driven by the parabolic-trough concentrated solar energy. Two-dimensional mathematical model of such surround filling reactor with numerical simulation was developed to evaluate its performance on eliminating the solar energy fluctuation. The effects of PCM with different thermophysical properties on chemical performance of the reactor were conducted when the sun is blocked. The optimal arrangement of multiple-stage PCMs was investigated and its performance under solar radiation fluctuations was investigated to improve the available latent heat of PCM and chemical performance of the reactor. The results showed that the PCM filling in the reactor significantly increased the time of methanol reforming reaction and improved the chemical performance when the heating by concentrated solar energy was ceased. PCM with lower phase change temperature and more latent heat could maintain the chemical reaction for a longer time. However, better chemical performance when PCM released latent heat could be achieved by PCM with higher phase change temperature. Compared to single PCM filling, Two-stage PCMs reached a maximum relative improvement in methanol conversion of 10.86%. Three-stage PCMs reached the maximum relative enhancement in methanol conversion of 11.36% compared to Two-stage PCMs. Under the cyclic and solar fluctuations, the multiple-stage PCMs reactor produced nearly twice as much hydrogen as that of the reactor without PCM. During a 6-h real solar radiation fluctuation, the multiple-stage PCMs reactor also have better methanol conversion. However, more than Three-stage PCMs arrangement improved the chemical performance of reactor only slightly.     

Effect of the vacancy close to heat exchange wall on the heat transfer performance of the solid particles steam generator using waste heat in a methanol steam reforming hydrogen production system

With the massive consumption of fossil fuels and it resulted in significant carbon emissions, it is urgent to find an alternative clean energy source. Hydrogen has been regarded as one of the most promising energy candidates for the next generation. It is a great approach that methane steam reforming for hydrogen production by rational utilization of industrial waste heat, which significantly minimizes carbon emissions and develops methanol steam reforming technology. A solid particle steam generator based on the primary heat exchange method has been proposed, which can provide the heat and steam in the methanol steam reforming hydrogen production system. The quasi-two-dimensional packing heat transfer model of solid particles steam generator was set up.The effect of distance change between the vacancy and the cold wall and distance change between vacancies on heat transfer performance of the steam generator and hydrogen production capacity were studied. As the distance between the vacancy and the wall increases, the heat transfer performance of the steam generator gradually deteriorates, so the steam production of the steam generator decreases, and the system's hydrogen production capacity is reduced, the maximum of the heat flux and the minimum of the apparent thermal resistance are 34.67 kW/m² and 12.02 K/W, respectively. As the distance between vacancies increases, the heat transfer performance of the steam generator is gradually optimized slightly. To maintain the hydrogen production capacity, vacancies should be avoided to appear 2 layers of particles away from the heat exchange wall in the particles steam generator. From the results of the study, the farther the distance between vacancies, the better the steam production and hydrogen production capacity.     

Thermal analysis of a micro tubular reactor for methanol steam reforming by optimizing the multilayer arrangement of catalyst bed for the catalytic combustion of methanolr

Packed bed tube reactors are commonly used for hydrogen production in proton exchange membrane fuel cells. However, the hydrogen production capacity of methanol steam reforming (MSR) is greatly limited by the poor heat transfer of packed catalyst bed. The hydrogen production capacity of catalyst bed can be effectively improved by optimizing the temperature distribution of reactor. In this study, four types of reactors including concentric circle methanol steam reforming reactor (MSRC), continuous catalytic combustion methanol steam reforming reactor (MSRR), hierarchical catalytic combustion methanol steam reforming reactor (MSRP) and segmented catalytic combustion reactor with fins (MSRF) are designed, modeled, compared and validated by experimental data. It was found that the maximum temperature difference of MSRC, MSRR, MSRP and MSRF reached 72.4 K, 58.6 K, 19.8 K and 11.3 K, respectively. In addition, the surface temperature inhomogeneity U_f and CO concentration of the MSRF decreased by 69.8% and 30.7%, compared with MSRC. At the same reactor volume, MSRF can achieve higher methanol conversion rate, and its effective energy absorption rate is 4.6%, 3.9% and 2.6% higher than that of MSRC, MSRR and MSRP, respectively. The MSRF could effectively avoid the influence of uneven temperature distribution on MSR compared with the other designs. In order to further improve the performance of MSRF, the influences of methanol vapor molar ratio, inlet temperature, flow rate, catalyst particle size and catalyst bed porosity on MSR were also discussed in the optimal reactor structure (MSRF).     

Effects of particle sizes on methanol steam reforming for hydrogen production in a reactor heated by waste heat

This paper reports the effects of particle sizes on methanol steam reforming for hydrogen production in a reactor heated by waste heat. The unsteady model was set up, which has been applied to investigate the effects of particle sizes (1.77 mm–14.60 mm) on particle temperature, heat transfer quantity, overall coefficient of heat-transfer, etc. The heat transfer performance of waste heat recovery heat exchanger is improved when the particle size increases, which is conducive to increase hydrogen production. The particle temperature change rate, the specific enthalpy change rate, the moving velocity of the maximum heat release rate particle, the contribution rate of solid phases, the heat release rate and the overall coefficient of heat-transfer increase, but the effective time of heat transfer decreases. When the particle size increases from 1.77 mm to 14.60 mm, the solid phase average contribution rate increases from 89.43% to 94.03%, the overall coefficient of heat-transfer increases from 1.39 W m⁻² K⁻¹ to 13.41 W m⁻² K⁻¹, the heat release rate increases from 48.9% to 99.9% and the effective time of heat transfer reduces from 48 h to 6.7 h.     

Design and performance evaluation of flexible tubular microreactor for methanol steam reforming reaction

To obtain the flexible microreactor for potential application in constrained space, a novel flexible tubular microreactor was designed by using a corrugated shell and a high porosity porous copper fiber rod (PCFR) as catalyst support. The effect of placement position, bending direction, and bending angle on reaction performance of flexible tubular microreactor was investigated. Then, the stability of flexible tubular microreactor was further evaluated. The experimental results showed that the placement position and bending direction had a significant influence on the reaction performance of flexible tubular microreactor. Methanol conversion of flexible tubular microreactor with the vertical placement was 6.67% higher than that with horizontal placement. Higher methanol conversion and H₂ flow rate were obtained when the microreactor bent along the vertical direction. The reaction performance of flexible tubular microreactor was found to decrease as the bending angle increased, and the methanol conversion decreased by around 14.07% with a bend of 90°. When the flexible tubular microreactor was horizontal placed with a bend of 60° in the vertical direction, the reaction performance of microreactor was not changed little after 20 cyclic bending. After continuous bending for 10 h, the methanol conversion and H₂ flow rate of flexible tubular microreactor were 70.58% and 0.88 mol/h, showing good reaction performance.     

Thermodynamic performance analysis of the influence of multi-factor coupling on the methanol steam reforming reaction

This work presents the H₂ production from methanol steam reforming (MSR) process by thermodynamic equilibrium analysis using the Gibbs free energy minimization method and multi-factor coupling method. To determine desirable procedure parameters with maximum methanol conversion and H₂ content and minimum CO content, the impacts of the temperature: 100–400 °C, steam-to-methanol (S/C) molar ratio: 1.0–3.0, and pressure: 0.5–3.0 atm were investigated. The dominant factor under the action of multiple factors and the specific influence of each factor on the MSR process were verified, simultaneously. For proton exchange membrane fuel cell (PEMFC), to keep the CO content of the reformate within a desired range, and under the premise of complete methanol conversion, the MSR process can be operated at lower temperature, higher S/C ratio and atmospheric pressure. Combined with practice process, the optimum values of the temperature, S/C ratio and pressure to produce reformate were identified to be 200–300 °C,1.6–2.0 and 1.0 atm, respectively.     

Numerical study of heat and mass transfer in a plate methanol steam micro reformer with methanol catalytic combustor

A numerical study is performed to examine the characteristics of heat and mass transfer and the performance of a plate methanol steam micro reformer with a methanol catalytic combustor. The effects of the flow configurations for co- and counter-current flows are explored in the present study. The influences of the Reynolds number (Re) and various geometric parameters on heat and mass transfer phenomena in the channels are also investigated numerically. It is expected that the Reynolds number (Re) and various geometric parameters can be improved by thermal management to enhance the chemical reaction and thus augment the micro reformer performance. Comparing the co- and counter-current flows via numerical simulation, the results show that the methanol conversion for counter-current flow could be improved by 10%. This is due to the fact that counter-current flow leads to a better thermal management, which in turn improves fuel conversion efficiency. With a higher Reynolds number on the combustor side, the wall temperature is increased and the methanol conversion can thus be enhanced. Meanwhile, a reduced Reynolds number on the micro reformer side would increase the methanol conversion. The results also reveal that appropriate geometric parameters exist for a micro reformer with a combustor to obtain better thermal management and methanol conversion.     

Experimental assessment of heat storage properties and heat transfer characteristics of a phase change material slurry for air conditioning applications

A new microencapsulated phase change material slurry based on microencapsulated Rubitherm RT6 at high concentration (45% w/w) was tested. Some heat storage properties and heat transfer characteristics have been experimentally investigated in order to assess its suitability for the integration into a low temperature heat storage system for solar air conditioning applications. DSC tests were conducted to evaluate the cold storage capacity and phase change temperature range. A phase change interval of approximately 3 °C and a hysteresis behaviour of the enthalpy were identified. An experimental set-up was built in order to quantify the natural convection heat transfer occurring from a vertical helically coiled tube immersed in the phase change material slurry. First, tests were carried out using water in order to obtain natural convection heat transfer correlations. Then a comparison was conducted with the results obtained for the phase change material slurry. It was found that the values of the heat transfer coefficient for the phase change material slurry were higher than for water, under identical temperature conditions inside the phase change interval.     

Comparison between 1D and 2D numerical models of a multi-tubular packed-bed reactor for methanol steam reforming

The hydrogen-rich gas produced in-situ by methanol steam reforming (MSR) reactions significantly affects the performance and endurance of the high-temperature polymer electrolyte membrane (HT-PEM) fuel cell stack. A numerical study of MSR reactions over a commercial CuO/ZnO/Al₂O₃ catalyst coupling with the heat and mass transfer phenomena in a co-current packed-bed reactor is conducted. The simulation results of a 1D and a 2D pseudo-homogeneous reactor model are compared, which indicates the importance of radial gradients in the catalyst bed. The effects of geometry and operating parameters on the steady-state performance of the reactor are investigated. The simulation results show that the increases in the inlet temperature of burner gas and the tube diameter significantly increase the non-uniformity of radial temperature distributions in reformer tubes. Hot spots are formed near the tube wall in the entrance region. The hot-spot temperature in the catalyst bed rises with the increase in the inlet temperature of burner gas. Moreover, the difference in simulation results between the 1D and 2D models is shown to be primarily influenced by the tube diameter. With a methanol conversion approaching 100% or a relatively small tube diameter, the simplified 1D model can be used instead of the 2D model to estimate the reactor performance.     

Design of a methanol reformer for on-board production of hydrogen as fuel for a 3 kW High-Temperature Proton Exchange Membrane Fuel Cell power system

The method of Computational Fluid Dynamics is used to predict the process parameters and select the optimum operating regime of a methanol reformer for on-board production of hydrogen as fuel for a 3 kW High-Temperature Proton Exchange Membrane Fuel Cell power system. The analysis uses a three reactions kinetics model for methanol steam reforming, water gas shift and methanol decomposition reactions on Cu/ZnO/Al₂O₃ catalyst. Numerical simulations are performed at single channel level for a range of reformer operating temperatures and values of the molar flow rate of methanol per weight of catalyst at the reformer inlet. Two operating regimes of the fuel processor are selected which offer high methanol conversion rate and high hydrogen production while simultaneously result in a small reformer size and a reformate gas composition that can be tolerated by phosphoric acid-doped high temperature membrane electrode assemblies for proton exchange membrane fuel cells. Based on the results of the numerical simulations, the reactor is sized, and its design is optimized.     

Heat transfer characteristics of microencapsulated phase change material slurry in laminar flow under constant heat flux

Due to its large apparent specific heat during the phase change period, microencapsulated phase change material slurry (MPCMS) has been suggested as a medium for heat transfer. In this paper, the convective heat transfer characteristics of MPCMS flowing in a circular tube were experimentally and numerically investigated. The enhanced convective heat transfer mechanism of MPCMS, especially in the thermal fully developed range, was analyzed by using the enthalpy model. Three kinds of fluid–pure water, micro-particle slurry and MPCMS were numerically investigated. The results show that in the phase change heat transfer region the Ste number and the Mr number are the most important parameters influencing the Nusselt number fluctuation profile and the dimensionless wall temperature. Re_b, d_p and c also influence the Nusselt number profile and the dimensionless wall temperature, but they are independent of phase change process.     

Numerical predictions on thermal characteristic and performance of methanol steam reforming with microwave-assisted heating

Microwave irradiation is an effective route to trigger methanol steam reforming (MSR) for hydrogen production because of the double absorption of microwaves by both the reagents and the catalyst. To recognize the thermal characteristic and performance of MSR in an environment with microwave irradiation, a numerical method is employed to predict the coupling phenomena of electromagnetic field, flow field and chemical reactions. Methanol decomposition (MD) is also regarded while MSR proceeds. Two sets of complex relative permittivity are established to account for the transmission of electromagnetic waves to heat reactants in the non-porous zone and the porous zone. Moreover, the effects of heat loss, microwave power and reagent flow rate on MSR are taken into account. The predictions suggest that heat loss is an important factor when the appropriate models with microwave-assisted heating are developed. A higher power is conducive to the performance of MSR, resulting from more heat generated in the reaction tube. At a given microwave power, heat generation due to microwave irradiation is independent of Reynolds number. As a result, increasing Reynolds number lessens methanol conversion and H₂ yield, as a consequence of more reagents passing through the catalyst bed. However, it is of interest that there exists an optimal Reynolds number for MSR to consume heat stemming from microwave irradiation.     

Solving heat transfer problems with phase change via smoothed effective heat capacity and element-free Galerkin methods

This paper presents a smoothed effective heat capacity model that is combined with element-free Galerkin (EFG) method, to solve heat transfer problems with phase change. The Sigmoid function is employed to build a continuous and smooth effective heat capacity function, so as to avoid possible error caused by the step-jump. The proposed numerical model is verified via numerical examples, and the effects of arrangement of EFG nodes and parameters relevant with Sigmoid function on the solutions are investigated. Satisfactory results are achieved in comparison with analytical solutions.     

Thermal behavior and hydrogen production of methanol steam reforming and autothermal reforming with spiral preheating

The present study aims to investigate the thermal behavior and hydrogen production characteristics from methanol steam reforming (MSR) and autothermal reforming (ATR) under the effects of a Cu-Zn-based catalyst and spiral preheating. Two different reaction temperatures of 250 and 300 °C are taken into account. Meanwhile, the O/C ratio (i.e. the molar ratio between O₂ and methanol) and S/C ratio (i.e. the molar ratio between steam and methanol) are controlled in the ranges of 0-0.5 and 1-2, respectively. The condition of O/C = 0 represents the reaction of MSR. By monitoring the supplied power into the reactor with a fixed gas hourly space velocity (GHSV) of 72,000 h⁻¹, the experimental results indicate that an exothermic reaction from ATR can be attained once the O/C ratio is as high as 0.125. Increasing O/C ratio causes more heat released from the reaction, this results in the decrease in the frequency of supplied power, especially at O/C = 0.5. It is noted that the concentration of CO in the product gas is quite low compared to that of CO₂. An increase in O/C ratio abates the concentration of H₂ from the consumption of per mol methanol; however, the H₂ yield in terms of thermodynamic analysis is increased. On account of the utilization of spiral preheating on the reactants, within the investigated operating conditions the methanol conversion and hydrogen yield were always higher than 95 and 90%, respectively. A comparison suggests that the methanol conversion from ATR of methanol with spiral preheating is superior to those of other studies.     

Design of a solar-driven methanol steam reforming receiver/reactor with a thermal storage medium and its performance analysis

A novel method of triple line focused on solar-powered receiver/reactor with a thermal storage medium for methanol steam reforming (MSR) hydrogen production is proposed in this paper. The photo-thermal-chemical energy conversion and coupling equations of the receiver/reactor are established, and the dynamic regularity between solar radiation and the hydrogen production characteristics is obtained by numerical simulation. The results show that a high solar radiation intensity helps to stabilize the duration of the reaction. For every 100 W m⁻² increase in the solar radiation intensity, the duration of the reaction maintained at the phase change point temperature of the phase change material (PCM) increases by approximately 11%. The daily hydrogen production performance of the system in Kunming (102°43′E and 25°02′N) during typical solar days is studied. The average annual total hydrogen production per unit of the lighting area is approximately 1300 m³. This research can guide similar issues related to solar thermochemical technology.     

等热流圆管内相变微胶囊悬浮液层流换热实验研究

用基液代替水来配置微胶囊相变悬浮液,并对实验数据的准确性进行了检验。在等热流密度环境下对管道内的该悬浮液进行加热实验,对相变微胶囊悬浮液的质量分数、St、入口过冷度、粒径和Re等因素影响强化换热的效果进行了分析。结果显示影响微胶囊相变悬浮液管内层流换热最主要的因素是微胶囊的质量分数和St。     

壳管式相变蓄热器传热效率研究

设计了一套定量测试不同工况下壳管式相变蓄热器传热效率装置。采用壳管式相变储热,石蜡填充入壳管间,管内通入冷、热载流体,模拟吸热放热过程。测试发现:相同入口条件下,单位时间传热量随入口水温增加呈线性增加;管内载流体流量加大有助于提高传热水平,15~60 L/h流量内单位时间传热量增速随流量增加放缓;不同材质传热管单位时间传热量变化并不明显,表明管道热阻在相变蓄热器总热阻中所占份额较小;相同工况下的蓄热过程,热载流体由下向上流动传热形式明显优于由上向下管排形式;尝试在封装相变材料中添加金属网状结构,强化相变材料内部热传导速率,对比发现相同工况下相变材料中添加金属网状结构,可提高10%~15%左右传热量。