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 micro-reactors, 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 W to 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 a 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/(h·g_catalyst)) were tested to understand the throughput achievable using this setup. This approach demonstrates improved scope and feasibility for further intensification compared to conventionally heated micro-reactors. The research paves the way for efficient and compact micro-reactors for fuel reforming processes.