Resistive Heating Catalytic Micro-Reactor for Process Intensified Fuel Reforming to Hydrogen

Process intensification of fuel reforming using micro-reactors has become crucial for feed flexibility in H2 production for fuel cells. In the literature on microreactors, energy supply for these endothermic reactions has faced limitations, relying on external heating, or autothermal operation. This paper explores a novel approach using a thin-film catalytic heater to develop micro-reactors. The study focuses on dry methane reforming in a simplified micro-reactor where thermal energy is supplied through electric resistive heating of a thin carbon sheet with a catalyst applied to its surface. The thin catalytic heated layer inside the reactor minimizes energy losses and the reactor footprint. Power input was varied from 90-225 W to understand its impact on the reactor temperature, CH4 conversion, H2 and CO yields. Fast thermal response times were achieved using the carbon paper as thin film for heating. Ni/MgO impregnated onto carbon paper was utilized as the catalytic heating element which resulted in CH4 conversions greater than 60% at temperature above750 K. Influence of operating conditions such as the input molar ratio of CO2/CH4, and gas hourly space velocity (GHSV) were also investigated to understand the scope of the catalyst in this setup. High GHSVs (592,885 and 948,617 mL/(hr.gcatalyst)) were tested to understand the throughput achievable using this setup. This approach demonstrates improved scope and feasibility for further intensification compared to conventionally heated microreactors. The research paves the way for efficient and compact micro-reactors for fuel reforming processes.