A computational-fluid-dynamics study on scaling up a single flat membrane reactor for on-site hydrogen production

The accessibility of hydrogen stations has been problematic for remote areas, although the demand for fuel-cell electric vehicles has risen. We propose a 50-Nm3/h on-site hydrogen production system using the accessible liquid-fuel infrastructure. The system integrates a pressurized steam reformer and a catalytic membrane reactor to produce high-purity hydrogen. This study focuses on scaling up our membrane reactor for enhanced hydrogen permeation while maintaining acceptable similarity and performance to make the system compact and effective. We compare three scale-up methods, which keep the inlet Reynolds number, gas hour space velocity, and Damko center dot hler-Peclet number constant, respectively. After selecting the third case for its best similarity, we increase the scale to eight and conclude that any scale beyond four is not ideal for our specific membrane reactor. By increasing the scale to four, we reduce the number of reactors for the 50 Nm3/h target by 91% while achieving a hydrogen recovery of 91%. Future studies can refer to the scale-up process that maintains the reactor similarity and high performance in this work for choosing an appropriate scale for membrane reactors.