Direct electrification of Rh/Al2O3 washcoated SiSiC foams for methane steam reforming: An experimental and modelling study

Electrified methane steam reforming (eMSR) is a promising concept for low-carbon hydrogen production. We investigate an innovative eMSR reactor where SiSiC foams, coated with Rh/Al₂O₃ catalyst, act as electrical resistances to generate the reaction heat via the Joule effect. The novel system was studied at different temperatures, space velocities, operating pressures and catalyst loadings. Thanks to efficient heating, active catalyst and optimal substrate geometry, complete methane conversions were observed even at a high space velocity of 200000 Nl/h/kg_cat. A specific energy demand as low as 1.24 kWh/Nm³_H2, with an unprecedented energy efficiency of 81%, was achieved on a washcoated foam with catalyst density of 86.3 g/L (GHSV = 150000 Nl/h/kg_cat, S/C = 4.1, ambient pressure). A mathematical model was validated against measured performance indicators and used to design an intensified eMSR unit for small scale H₂ production.