Abstract
For the increasing demand for fuel flexibility in H2 production for fuel cells, the process intensification of fuel reforming using micro-reactors has become crucial. While prior literature has seen substantial progress in hydrocarbon fuel reforming within micro-reactors employing micro-channels, the supply of thermal energy for these endothermic reactions has faced limitations, relying on external heating, or operating in autothermal mode through partial combustion. This paper explores a novel approach by investigating the use of a thin-film catalytic heater for the development of micro-reactors. The study specifically focuses on dry methane reforming, showcasing 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 resides inside the reactor, minimizing energy losses and significantly reducing the overall reactor footprint. Power input was varied from 90 W to 225 W to understand its impact on the temperature achieved inside the reactor, extent of CH4 conversion, H2 and CO yields. Fast thermal response times were achieved due to the use of carbon paper as thin film for heating. Ni/MgO impregnated onto the carbon paper was utilized as the catalytic heating element which resulted in CH4 conversions greater than 60% at temperature greater than 750 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 extent of 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 more efficient and compact micro-reactors, addressing challenges associated with thermal energy supply in the context of fuel reforming processes.
