Numerical simulation and experimental study of hydrogen production from dimethyl ether steam reforming in a micro-reactor

To enhance the heat and mass transfer during dimethyl ether (DME) steam reforming, a micro-reactor with catalyst coated on nickel foam support was designed and fabricated. A two-dimensional numerical model with SIMPLE algorithm and finite volume method was used to investigate 1) the fluid flow, 2) the heat transfer and 3) chemical reactions consist of DME hydrolysis, methanol steam reforming, methanol decomposition and water gas shift reactions. Both the numerical and the experimental results showed that the DME conversion in the micro-reactor is higher than that in the fixed bed reactor. The numerical study also showed that the velocity and the temperature distribution were more uniform in the micro-reactor. Wall temperature, porosity and steam/DME ratio have been investigated in order to optimize the process in the micro-reactor. The wall temperature of 270 °C and the steam/DME feed ratio of 5 were recommended. Meanwhile the results indicate that a larger porosity will give a higher DME conversion and CO concentration.     

Effect of Cr promoter on performance of steam reforming of dimethyl ether in a metal foam micro-reactor

The CuZnAl/HZSM-5, CuZnAlCr/HZSM-5, CuZnAlZr/HZSM-5, CuZnAlCo/HZSM-5, and CuZnAlCe/HZSM-5 catalysts that were prepared by a co-precipitation method was used for hydrogen production from steam reforming of dimethyl ether (SRD) in a metal foam micro-reactor. These catalysts were characterized by means of XRD, TPR, SEM and BET surface areas. The results showed that promoter Cr can reduce the average pore diameter and reduction temperature of catalyst. The conversion of dimethyl ether and hydrogen yield reaches 99% and 95% respectively over CuZnAlCr/HZSM-5 catalyst under a relatively lower reaction temperature. The obtained hydrogen-riched gas is easy to purify and meet the need of polymer electrolyte membrane fuel cell. The effects of reaction temperature, space velocity and steam to DME ratio on SRD were investigated in a metal foam micro-reactor. At the conditions of T = 250 °C, the space velocity of 3884 ml/(g h), steam to DME = 5, DME conversion of >97% were obtained over the CuZnAlCr/HZSM-5 catalyst without obvious deactivation during 50 h.     

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

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

Intensification of hydrogen production from methanol steam reforming by catalyst segmentation and metallic foam insert

This paper is a numerical study about the catalyst morphology CuO/ZnO/Al₂O₃ effects on the hydrogen production from methanol steam reforming, for proton exchange membrane fuel cells (PMEFC). The study is focused on the influences of the metal foam insert, catalyst layer segmentation, and metal foam as catalyst support on the reactor performance: hydrogen yield and methanol conversion. According to the carried simulations, it is found that these configurations improve the reformer performances compared to the continuous catalyst layer configuration. The insertion of metal foam increases the efficiency of up to 75.41% at 525 K. Also, at this reaction temperature, the segmentation of the catalyst layer in similar parts increases the reformer efficiency by 2.11%, 4.23%, 6.77%, and 8.6% for 2, 4, 8, and 16 identical parts, respectively. As well as, the metal foam as catalyst support is more efficient compared to the other configurations, the efficiency is equal to 64% at T = 495 k.     

Hydrogen production from ethanol steam reforming in a micro-channel reactor

Ethanol steam reforming was studied over a supported Ir/CeO₂ catalyst in a micro-channel structured reactor. The catalyst coating was deposited on the channel walls and showed a remarkably high homogeneity and an excellent adherence to the stainless steel substrate, leading to stable performance during long-term runs. Hydrogen yields exceeding 40 L_H2 g_cat⁻¹ h⁻¹ were achieved during testing with partial ethanol conversion of 65% and a residence time in the order of a few milliseconds. This hydrogen productivity was found significantly higher than in a comparable conventional fixed-bed reactor hence being extremely promising for hydrogen production in micro fuel cell applications.     

CFD simulation with detailed chemistry of steam reforming of methane for hydrogen production in an integrated micro-reactor

micro-reactor has drawn more and more attention in recent years due to the process intensification on basic transport phenomena in micro-channels, which would often lead to the improved reactor performance. Steam reforming of methane (SRM) in micro-reactor has great potential to realize a low-cost, compact process for hydrogen production via an evident shortening of reaction time from seconds to milliseconds. This work focuses on the detailed modeling and simulation of a micro-reactor design for SRM reaction with the integration of a micro-channel for Rh-catalyzed endothermic reaction, a micro-channel for Pt-catalyzed exothermic reaction and a wall in between with Rh or Pt-catalyst coated layer. The elementary reaction kinetics for SRM process is adopted in the CFD model, while the combustion channel is described by global reaction kinetics. The model predictions were quantitatively validated by the experimental data in the literature. For the extremely fast reactions in both channels, the simulations indicated the significance of the heat conduction ability of the reactor wall as well as the interplay between the exothermic and endothermic reactions (e.g., the flow rate ratio of fuel gas to reforming gas). The characteristic width of 0.5 mm is considered to be a suitable channel size to balance the trade-off between the heat transfer behavior in micro-channels and the easy fabrication of micro-channels.     

Simulation of methane steam reforming in a catalytic micro-reactor using a combined analytical approach and response surface methodology

In this study, a steady-state analytical model for heat and mass transfer in a 2D micro-reactor coated with a Nickel-based catalyst is developed to investigate microscale hydrogen production. Appropriate correlations for each species’ net rate of production or consumption, mass diffusivity, and the heat of reactions are developed using a detailed reaction mechanism of methane steam reforming. The energy and species conservation equations are then solved for the reactive mixture coupled with the wall energy equation. Finally, the response surface methodology (RSM) is employed to study the effects of channel height, inlet velocity and temperature, wall thickness and conductivity, and external heat flux on CH4 conversion. It is found that the inlet gas temperature, among different parameters, has the most influence on the overall performance of the microchannel hydrogen production. Also, the maximum necessary heat of reforming reaction increases by 84% and 26% if the CH₄ conversion changes from 50% to 60% and 60% to 70%, respectively. The developed analytical simulation can be a useful tool for designing experiments in micro-scale hydrogen production.     

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.     

Natural gas steam reforming for hydrogen production over metal monolith catalyst with efficient heat-transfer

Heat transfer performance of the natural gas (NG) steam reforming in a reactor bed with metal monolith catalyst has been evaluated in comparison with that in the conventional packed bed with pellet catalysts. 2%Ru/Al₂O₃ catalyst with high intrinsic activity has been wash-coated on metal monolith substrates or used as it was for the packed bed application. The prepared metal monolith catalyst has been applied for NG steam reforming to increase heat-transfer efficiency. Under the same degree of temperature gradient from the furnace wall to the catalyst bed, the heat flux obtained in the monolithic bed reactor was about twice higher than that in the packed bed reactor. Maximum heat transfer coefficient achieved in this study for the former was 0.65 kW/m² K, while that for the latter was 0.3 kW/m² K. This is mainly due to enhanced heat-transfer via metal monolith catalyst.     

Trapezoidal cavity for high reforming temperature performance of auto-thermal methanol steam reforming micro-reactor for hydrogen production

To realize high reforming temperature performance of auto-thermal methanol steam reforming micro-reactor (ATMSRM) for hydrogen production (HP) and enhance its long-term HP performance, a trapezoidal cavity on methanol steam reforming (MSR) chamber plate is proposed. A numerical simulation model of the ATMSRM for HP is built. The influence of different geometric sizes of the trapezoidal cavity on reforming temperature performance of ATMSRM is investigated by the numerical simulation model. The reforming temperature performance and HP performance of ATMSRMs using the optimal trapezoidal cavity, the combustion reaction support (CRS) with optimal multiple micro-channels and the non-optimization are compared. The reforming temperature performance and HP performance of the size-enlarged ATMSRM with the optimal trapezoidal cavity are also studied. The results show that compared to other trapezoidal cavities, reforming temperature difference per 1 °C (△TA) of the ATMSRM using the F-type trapezoidal cavity with 50 mm length, 76 mm width, 0.4 mm front end depth and 0.2 mm back end depth is smaller, which is 0.01709 °C °C^?1 under 0.9 mL/min combustion methanol injection rate and 4 mL/h reforming methanol-water mixture injection rate. Compared with ATMSRMs using the CRS with optimal multiple micro-channels and the non-optimization, ATMSRM using F-type trapezoidal cavity has a better comprehensive HP performance. Compared with non-enlarged ATMSRM using F-type trapezoidal cavity, size-enlarged ATMSRM using F-type trapezoidal cavity has bigger △TA, larger reforming methanol conversion rate, higher hydrogen yield and more carbon monoxide selectivity. This research work offers a new method for enhancing reforming temperature performance of ATMSRM for HP.     

Hydrogen generation characteristics of reduced DME steam reforming catalysts according to heating methods

The purpose of this study is to investigate the hydrogen generation characteristics of H₂-reduced dimethyl ether (DME) steam reforming (SR) catalysts using different heating processes. The effects of the H₂ reduction temperature and space velocity were investigated to identify an optimal reaction environment. Both the resistive and induction heating methods were used. The catalysts were prepared by impregnating copper over a γ-Al₂O₃ support. The Cu/Al₂O₃ catalysts with different loading amounts of 5–15 wt% Cu exhibited different characteristics when subjected to hydrogen reduction. The variation in acidity had a dominant effect on the DME-SR activity, and 15Cu/Al₂O₃ that underwent hydrogen reduction treatment at 500 °C attained improved performance at low temperatures and low formation of by-products, allowing for the achievement of its highest H₂ concentration of 74.08% at 375 °C. The induction heating reactor had an energy consumption that was about 25% lower than that of the resistive heating reactor.     

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

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

Effects of structural parameters on the performance of a micro-reactor with micro-pin-fin arrays (MPFAR) for hydrogen production

To enhance the energy conversion efficiency of the micro-reactor with micro-pin-fin arrays (MPFAR) for hydrogen production, the effect of structural parameters (the height of the micro-pin-fin, the transverse and longitudinal center distance between two adjacent micro-pin-fins) on the performance of the MPFAR for hydrogen production is investigated. Based on the geometrical parameters, a theoretical model of material balance for hydrogen production in the MPFAR is established. The calculated results show that with the increase of the micro-pin-fin height or the decrease of the distance between two adjacent micro-pin-fins, the methanol conversion rate and the CO molar fraction increase. The methanol conversion rate increases by about 10% when the height of micro-pin-fin increases from 0.2 to 1 mm or the center distance between the two adjacent micro-pin-fins increases from 1.2 to 2.6 mm. The comparisons between the experimental and calculated results validate the theoretical model of material balance utilized in this study. Finally, a better geometrical structure of micro-pin-fin arrays is obtained, in which the height of the micro-pin-fin, the transverse and longitudinal center distances between two adjacent micro-pin-fins are 1.0 mm, 1.2 mm and 1.2 mm, respectively. The hydrogen yield in the MPFAR can reach about 8.3 ml/min under the condition that the methanol conversion rate is above 90%.     

Recent trends in the development of reactor systems for hydrogen production via methanol steam reforming

Hydrogen is currently receiving significant attention as an alternative energy resource, and among the various methods for producing hydrogen, methanol steam reforming (MSR) has attracted great attention because of its economy and practicality. Because the MSR reaction is inherently activated over catalytic materials, studies have focused on the development of noble metal-based catalysts and the improvement of existing catalysts with respect to performance and stability. However, less attention has been paid to the modification and development of innovative MSR reactors to improve their performance and efficiency. Therefore, in this review paper, we summarize the trends in the development of MSR reactor systems, including microreactors and membrane reactors, as well as the various structured catalyst materials appropriate for application in complex reactors. In addition, other engineering approaches to achieve highly efficient MSR reactors for the production of hydrogen are discussed.     

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

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

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

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

Hydrogen production by glycerol steam reforming with in situ hydrogen separation: A thermodynamic investigation

Thermodynamic features of hydrogen production by glycerol steam reforming with in situ hydrogen extraction have been studied with the method of Gibbs free energy minimization. The effects of pressure (1–5 atm), temperature (600–1000 K), water to glycerol ratio (WGR, 3–12) and fraction of H₂ removal (f, 0–1) on the reforming reactions and carbon formation were investigated. The results suggest separation of hydrogen in situ can substantially enhance hydrogen production from glycerol steam reforming, as 7 mol (stoichiometric value) of hydrogen can be obtained even at 600 K due to the hydrogen extraction. It is demonstrated that atmospheric pressure and a WGR of 9 are suitable for hydrogen production and the optimum temperature for glycerol steam reforming with in situ hydrogen removal is between 825 and 875 K, 100 K lower than that achieved typically without hydrogen separation. Furthermore, the detrimental influence of increasing pressure in terms of hydrogen production becomes marginal above 800 K with a high fraction of H₂ removal (i.e., f = 0.99). High temperature and WGR are favorable to inhibit carbon production.     

Effect of inert metal foam matrices on hydrogen production intensification of methane steam reforming process in wall-coated reformer

Numerical modeling of a heated mixture of methane with steam in 2D plane Wall-Coated Steam Methane Reformer (WC-SMR) with surface catalytic reaction at industrial conditions has been performed. The modeling was performed within the framework of Navier-Stokes equations for a laminar flow of a multi-component compressible gas. The influence of the insertion of non-catalytic nickel-based metal foam matrices in the catalytic zone of the WC-SMR on the hydrodynamic, thermal and mass behaviors of the gas mixture and its distribution along the reactor have been investigated. Three different Metal Foam (MF) samples have been investigated and then compared: Ni-Foam, Ni-Cr-Foam and Ni-Fe-Cr-Foam. It has been shown that not only the use of metal foam matrices but also their thermo-physical properties are important to improving the WC-SMR efficiency. It is demonstrated that such material can bring a significant enhancement for hydrogen production, heat and mass transfer processes. 16.91% of improvement in terms of H₂ production is realized.     

A combined system of dimethyl ether (DME) steam reforming and lean NOx trap catalysts to improve NOx reduction in DME engines

This paper performs a study on a combined system of DME steam reforming (SR) and lean NOx trap (LNT) in order to improve the performance of the de-NOx catalyst in DME engines. A new concept, a combined system of SR and LNT catalysts, utilizes H₂ and CO generated from the DME SR catalyst as a reductant for the LNT catalyst. The Cu-based SR catalyst was prepared by the sol-gel method; further, the LNT catalyst was used a commercial catalyst. The parameters considered in this experiment included the particle size, dispersion, and amount of Cu loaded on the SR catalyst, the cell density of the substrate of the SR catalyst, and the amount of Zn as a promoter. The experiments revealed that the highest NOx conversion was obtained in the LNT catalyst when the concentration of DME was 1% and the lean/rich time was 55/8 s; however, we decided to supply 0.7% of DME and use 55/5 s of lean/rich time in the combined system of SR and LNT to overcome the problems of DME slip and fuel penalties. The system showed the best performance regarding NOx conversion in the combined system of SR and LNT that used the Cu29Zn1/r-Al₂O₃ catalyst with 1% of Zn as a promoter, a cell density of 600 cpsi, and a volumetric ratio of 1.3 (SR/LNT). Finally, the NOx conversion was improved by about 20% compared to the LNT catalyst used alone.     

Hydrogen production by sorption enhanced steam reforming of propane: A thermodynamic investigation

Thermodynamic features of hydrogen production by sorption enhanced steam reforming (SESR) of propane have been studied with the method of Gibbs free energy minimization and contrasted with propane steam reforming (SR). The effects of pressure (1-5 atm), temperature (700-1100 K) and water to propane ratio (WPR, 1-18) on equilibrium compositions and carbon formation are investigated. The results suggest that atmospheric pressure and a WPR of 12 are suitable for hydrogen production from both SR and SESR of propane. High WPR is favourable to inhibit carbon formation. The minimum WPR required to eliminate carbon production is 6 in both SR and SESR. The most favourable temperature for propane SR is approximately 950 K at which 1 mol of propane has the capacity to produce 9.1 mol of hydrogen. The optimum temperature for SESR is approximately 825 K, which is over 100 K lower than that for SR. Other key benefits include enhanced hydrogen production of nearly 10 mol (stoichiometric value) of hydrogen per mole of propane at 700 K, increased hydrogen purity (99% compared with 74% in SR) and no CO₂ or CO production with the only impurity being CH₄, all indicating a great potential of SESR of propane for hydrogen production.