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.     

Autothermal hydrogen generation from methanol in a ceramic microchannel network

In this paper, the authors present the first demonstration of a new class of integrated ceramic microchannel reactors for all-in-one reforming of hydrocarbon fuels. The reactor concept employs precision-machined metal distributors capable of realizing complex flow distribution patterns with extruded ceramic microchannel networks for cost-effective thermal integration of multiple chemical processes. The presently reported reactor is comprised of five methanol steam reforming channels packed with CuO/γ-Al₂O₃, interspersed with four methanol combustion channels washcoated with Pt/γ-Al₂O₃, for autothermal hydrogen production (i.e., without external heating). Results demonstrate the capability of this new device for integrating combustion and steam reforming of methanol for autothermal production of hydrogen, owing to the axially self-insulating nature of distributor-packaged ceramic microchannels. In the absence of any external insulation, stable reforming of methanol to hydrogen at conversions >90% and hydrogen yields >70% was achieved at a maximum reactor temperature of 400 °C, while simultaneously maintaining a packaging temperature <50 °C.     

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.     

Effect of molar ratio of water / ethanol on hydrogen selectivity in catalytic production of hydrogen using steam reforming of ethanol

As fossil energy resources are shrinking, the increase in global energy needs and environmental pollution paved the way to the search for new and renewable energy resources. Therefore, the future of energy technology is being built on the use of hydrogen, which is one of the cleanest and most efficient renewable energy sources, and steam reforming is becoming the utmost method to produce hydrogen. This study focuses on the operation condition of steam reforming of ethanol on catalyst materials, which were shaped using active metals such as Ni, Cu and Cs and supporting materials which were activated by carbon and LiAlO₂. These catalyst materials were tested to produce hydrogen gas using different water/ethanol mole ratio at different temperatures and a constant feed flow rate. The evaluation regarding hydrogen selectivity results and the percentage of hydrogen in the products revealed that NiCuCs/LiAlO₂ catalyst showed the highest performance at all water/ethanol ratios and temperatures between 300 and 600 °C.     

Hydrogen production from methane and natural gas steam reforming in conventional and microreactor reaction systems

Ni-based (over MgO and Al₂O₃) and noble metal-based (Pd and Pt over Al₂O₃) catalysts were prepared by wet impregnation method and thereafter impregnated in microreactors. The catalytic activity was measured at several temperatures, atmospheric pressure and different steam to carbon, S/C, ratios. These conditions were the same for conventional, fixed bed reactor system, and microreactors. Weight hourly space velocity, WHSV, was maintained equal in order to compare the activity results from both reaction systems. For microreactor systems, similar activities of Ni-based catalyst were measured in the steam methane reforming (SMR) activity tests, but not in the case of natural gas steam reforming tests. When noble metal-based catalysts were used in the conventional reaction system no significant activity was measured but all catalysts showed some activity when they were tested in the microreactor systems. The analysis by SEM and TEM revealed a carbon-free surface for Ni-based catalyst as well as carbon filaments growth in case of noble metal-based catalysts.     

Steam reforming of ethanol over nickel-tungsten catalyst

Ni-W/Al₂O₃ catalysts were synthesized, characterized and tested for the steam reforming of ethanol from 300 to 600 °C. Addition of Ni and W on the alumina, decreased the surface area and increased the pore volume of the mesoporous materials synthesized. The reaction products obtained were: H₂, CO₂, C₂H₄, CH₄, CO₂, CO and CH₃CHO. A promoting effect of Ni-W was observed in the conversion of ethanol to H₂ from 15 to 30 wt.% Ni and 1 wt.% W. The selectivity to H₂ on the alumina with Ni-W, was between 66.53 and 68.53% at 550 °C, appearing some undesirable products, with low ratio of CO/CO₂. Reaction was studied on a fixed bed reactor at atmospheric pressure with an ethanol/water molar ratio of 1:4, from 300 to 600 °C. The catalysts were characterized by the thermal gravimetric analysis (TGA)-Differential thermal analysis (DTA), N₂ physisorption (BET and BJH methods), X-ray diffraction (XRD) and scanning electron microscopy (SEM), these techniques were used for characterization, before and after of the steam reforming.     

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.     

Influence of regeneration conditions on cyclic sorption-enhanced steam reforming of ethanol in fixed-bed reactor

The effect of regeneration conditions on the cyclic sorption-enhanced steam reforming of ethanol (SESRE) in a fixed-bed reactor was investigated. Columnar Ni–Ca catalysts were used in the cyclic SESRE experiments. The effects of different parameters, including temperature, purge direction, and purge gas on the regeneration process were discussed. The experimental results reveal that the regeneration temperature strongly affected not only the CO₂ desorption rate but also the durability of the CaO sorbent. The stability of the CaO sorbent within the Ni–Ca catalyst was improved owing to the formation of Ca₁₂Al₁₄O₃₃. Moreover, the type of purge gas (N₂ or air) for regeneration had negligible effect on the CO₂ capture performance of the Ni–Ca catalyst. For regeneration by air purging, coke decomposition over the Ni–Ca catalyst was accompanied by a slight decline in the activity of the Ni catalyst, which was attributed to the cyclic Ni redox.     

Production of hydrogen by ethanol steam reforming on Co/Al2O3 catalysts: Effect of addition of small quantities of noble metals

The catalytic performance of Co/Al₂O₃ catalysts promoted with small amounts noble metals (Pt, Pd, Ru, Ir) for steam reforming of ethanol (SRE) has been investigated. The catalysts were characterized by the energy dispersive X-ray, X-ray diffraction, BET surface area, X-ray absorption fine structure and temperature reduction programmed techniques. The results showed that the promoting effect of noble metals included a marked decrease of the reduction temperatures of both Co₃O₄ and cobalt surface species interacting with the support due to the hydrogen spillover effect, leading to a significant increase of the reducibilities of the promoted catalysts. The better catalytic performance for the ethanol steam reforming at 400 °C was obtained for the CoRu/Al₂O₃ catalyst, which presented an effluent gaseous mixture with the highest H₂ selectivity and the reasonable low CO formation.     

A techno-economic evaluation of the hydrogen production for energy generation using an ethanol fuel processor

The techno-economic analysis of a process to convert ethanol into H₂ to be used as a fuel for PEM fuel cells of H₂-powered cars was done. A plant for H₂ production was simulated using experimental results obtained on monolith reactors for ethanol steam reforming and WGS steps. The steam reforming (Rh/CeSiO₂) and WGS (Pt/ZrO₂) monolith catalysts remained quite stable during long-term startup/shut down cycles, with no carbon deposition. The H₂ production cost was significantly affected by the ethanol price. The monolith catalyst costs contribution was lower than that of conventional reactors. The H₂ production cost obtained using the expensive Brazilian ethanol price (0.81 US$/L ethanol) was US$ 8.87/kg H₂, which is lower than the current market prices (US$ 13.44/kg H₂) practiced at H₂ refueling stations in California. This result showed that this process is economically feasible to provide H₂ as a fuel for H₂-powered cars at competitive costs in refueling stations.     

Novel zeolite-supported rhodium catalysts for ethanol steam reforming

Renewable bioethanol is an interesting hydrogen source for fuel cells through steam reforming, but its C–C bond promotes parallel reactions, mainly coke and by-products formation. In this way, good ethanol reforming catalysts are still needed, which explains current research and development efforts around the world. Most catalysts proposed for ethanol reforming are based on oxide-supported noble metals with surface area below 100 m² g⁻¹ and reaction temperatures above 500 °C. Novel Rh and Rh–K catalysts supported on NaY zeolite with surface area above 440 m² g⁻¹ are presented in this work. Reaction temperature was fixed at 300 °C and H₂O/EtOH molar ratio and reagent flow were varied. Ethanol conversion varied from 50 to 99%, with average increase of 50% due to K promoter, and hydrogen production yield achieved 68%.     

Steam reforming of ethanol with zirconia incorporated mesoporous silicate supported catalysts

Steam reforming of ethanol is a promising route for the production of high purity hydrogen. Ni impregnated zirconia, with high chemical and thermal stability and high water adsorption-dissociation capability is an attractive catalyst for this reaction. In the present study, mesoporous zirconia and high surface area zirconia/silicate structured materials, such as Zr-SBA-15 and Zr-MCM-41, were synthesized following hydrothermal routes, using different surfactants as the structure directing templates. Surface area values of Ni impregnated mesoporous Zr-SBA-15 and Zr-MCM-41 catalysts with molar Zr/Si ratios of 0.13 and 0.45 were 515 and 338 m²/g, respectively. Ethanol reforming tests performed with these catalysts, in the temperature range of 550–650 °C, proved the potential of these materials to achieve very high hydrogen yields, over 90% of the maximum yield value of 6 mol per mole of ethanol reacted. Type of support material, Ni distribution and cluster size over the catalyst, reaction temperature and steam to ethanol ratio were found to have strong influence on coke formation and stability of hydrogen yield.     

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.     

An analytical and experimental investigation of high-pressure catalytic steam reforming of ethanol in a hydrogen selective membrane reactor

The objective of this work was to explore the benefits of high-pressure steam reforming of ethanol for the production of hydrogen needed to refuel the high-pressure tanks of fuel cell (polymer electrolyte) vehicles. This paper reports on the potential efficiency benefits and challenges of pressurized reforming and options for dealing with the challenges; it reports the results from experiments in a micro-reactor, followed by a modeling study of the reactor to project the dependence of the hydrogen yields on process parameters. The experiments were conducted in the range of approximately 7–70 atm, 600–750 °C, steam-to-carbon molar ratios of 3–12, and gas hourly space velocities of 8500–83,000 per hour. By placing a hydrogen-transporting palladium-alloy membrane within the catalyst zone, this study quantified the beneficial effect of hydrogen extraction from the reforming zone. The model was used to explore the parameter space to define the reactor and conditions that would be needed to approach the efficiency targets for distributed hydrogen production plants. The results indicate that the tested catalyst was sufficiently active, and the hydrogen yield achieved with the experimental membrane reactor was limited by the low hydrogen flux of the tested membrane. The reactor model predicts that a membrane with at least 20 times higher flux than currently evaluated would be sufficient to generate hydrogen yields to match efficiency targets of 72%.     

Thermodynamic analysis of hydrogen production by autothermal reforming of ethanol

Ethanol steam reforming (ESR) is a strong endothermic reaction and ideally it only produces hydrogen and carbon dioxide.     

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.     

Development of methanol steam reforming microreactor based on stacked wave sheets and copper foam for hydrogen production

Methanol steam reforming has been used for in-situ hydrogen production and supply for proton exchange membrane fuel cell (PEMFC), while its power density and energy efficiency still needs to be improved. Herein, we present a novel methanol steam reforming microreactor based on the stacked wave sheets and copper foam for highly efficient hydrogen production. The structural of stacked wave sheets and copper foam, and their roles in the microreactor are described, methanol catalytic combustion is adopted to supply heat for methanol steam reforming reaction and enables the microreactor to work automatically. For catalyst carrier, a fractal body-centered cubic model is established to study the flow characteristics and chemical reaction performances of the copper foam with coated catalyst layer. Both simulation and experimental results showed that the reformate flowrate increases with the increasing of microreactor layers and methanol solution flowrate, the discrepancies of methanol conversion between simulation and experimental tests are less than 7%. Experimental results demonstrated that the reformate flowrate of 1.0 SLM can be achieved with methanol conversion rate of 65%, the output power of the microreactor is 159 W and power density is 395 W/L. The results obtained in this study indicates that stacked wave sheets and copper foam can uniform the reactant flow and improve the hydrogen production performances.     

Hydrogen from ethanol: Theoretical optimization of a PEMFC system integrated with a steam reforming processor

In this paper the energetic optimization of a proton exchange membrane fuel cell integrated with a steam reforming system using ethanol as fuel is analysed. In order to obtain high hydrogen production, a thermodynamic analysis of the steam reforming process has been carried out and the optimal operating conditions has been defined. Moreover, the overall efficiency of the PEMFC-SR system has been investigated as a function of the fuel utilization factor and the effects of the anodic off-gas recirculation have been evaluated.     

Co catalysts modified by rare earths (La,Ce or Pr) for hydrogen production from ethanol

Co/MgAl₂O₄ catalysts modified with La, Pr or Ce were prepared, characterized by different techniques and tested in ethanol steam reforming reaction to produce hydrogen. The catalytic behavior at 650 °C depended on the nature of rare earth. The amount of carbon on promoted catalysts was significantly lower than that on unpromoted one. The Pr and La containing catalysts produced a high acetaldehyde selectivity which decreased the hydrogen production. The superior performance of the catalyst promoted with 7.8% Ce could be partially explained by a higher dispersion and a high reduction of Co species.