Recent Advances in the Development of Highly Conductive Structured Supports for the Intensification of Non-adiabatic Gas-Solid Catalytic Processes: The Methane Steam Reforming Case Study

Structured catalysts are strong candidates for the intensification of non-adiabatic gas-solid catalytic processes thanks to their superior heat and mass transfer properties combined with low pressure drops. In the past two decades, different types of substrates have been proposed, including honeycomb monoliths, open-cell foams and, more recently, periodic open cellular structures produced by additive manufacturing methods. Among others, thermally conductive metallic cellular substrates have been extensively tested in heat-transfer limited exo- or endo-thermic processes in tubular reactors, demonstrating significant potential for process intensification. The catalytic activation of these geometries is critical: on one hand, these structures can be washcoated with a thin layer of catalytic active phase, but the resulting catalyst inventory is limited. More recently, an alternative approach has been proposed, which relies on packing the cavities of the metallic matrix with catalyst pellets. In this paper, an up-to-date overview of the aforementioned topics will be provided. After a brief introduction concerning the concept of structured catalysts based on highly conductive supports, specific attention will be devoted to the most recent advances in their manufacturing and in their catalytic activation. Finally, the application to the methane steam reforming process will be presented as a relevant case study of process intensification. The results from a comparison of three different reactor layouts (i.e. conventional packed bed, washcoated copper foams and packed copper foams) will highlight the benefits for the overall reformer performance resulting from the adoption of highly conductive structured internals.

Mathematical Model of Steam Reforming in the Anode Channel of a Molten Carbonate Fuel Cell

The paper presents a mathematical model of a molten carbonate fuel cell with a catalyst in the anode channel. The modeled system is fueled by methane. The system includes a model of the steam reforming process occurring in the anode channel of the MCFC fuel cell and the model of the cell itself. A reduced order model was used to describe the operation of the molten carbonate fuel cell, whereas a kinetic model describes the methane steam reforming. The calculations of the reforming were done in Aspen HYSYS software. Four values of the steam-to-carbon ratio (2.0, 2.5, 3.0, and 3.5) were used to analyze the performance of the reforming process. In the first phase, the reaction kinetics model was based on data from the literature.

Peculiarities of hydrogen production using methane steam reforming in a microstructured reactor-heat exchanger

This paper presents the description of the rhodium catalyst synthesis and the results of numerical study of the methane-steam reforming in a microstructured reactor-heat exchanger. The kinetics of the reforming reactions on a synthesized catalyst was determined using the numerical simulations and experimental data on activation energy of the methane reactions. It allows finding the characteristics of methane steam reforming that can be used for optimization of the microstructured reactor implementing the microchannel technology.

An Enhanced Sherwood Number to Model the Hydrogen Transport in Membrane Steam Reformers

It is well known that membrane reactors are inherently two-dimensional systems in which species concentrations vary as a consequence of both the reaction and permeation across the membrane, which occurs in the direction perpendicular to that of the main gas flow. Recently, an expression for an enhanced Sherwood number was developed to describe the hydrogen concentration gradients arising in methane steam-reforming membrane reactors as a consequence of the combined effect of hydrogen production, dispersion, and permeation. Here, the analysis is developed in further detail with the aim of (i) assessing the validity of the simplifying assumptions made when developing the 1D model and (ii) identifying the operating conditions under which it is possible to employ the 1D model with the enhanced Sherwood number.

Elucidating the Role and Interplay of Nickel and Molybdenum Carbide Particles Supported on Zeolite Y in Methane-Steam Reforming

Methane steam reforming (MSR) reaction is a mature industrial process that has been applied for large-scale hydrogen production. Here, we report the synthesis and characterization, reaction kinetics, and deactivation mechanism of a series of catalysts with metallic nickel (Ni) clusters and molybdenum carbide (Mo2C) particles supported on zeolite Y (Ni-Mo2C/FAU) in MSR reaction at 850 oC. Despite low Ni loading less than 2.4 wt%, MSR on Ni-Mo2C/FAU exhibits high activity and stability, yet deactivation of Ni-FAU (the sample without Mo2C) is significant. Further investigations elucidate that the catalyst deactivation is caused by Ni particle sintering via Ostwald ripening instead of coking, and steam induces hydroxylated Ni surface that accelerates sintering. Moreover, encapsulated Mo2C boosts the activity and stability of Ni on zeolite Y by enhancing CH4 activation rather than activating H2O. The interplays among Mo2C and Ni particles dynamically balance the carbon formation and consumption rates, and inhibit Ni sintering. This study enables insights into an alternative design principle of transition metal carbide – Ni catalysts with high activity and stability for effective MSR by tuning the compositional, structural, and interfacial factors.