A novel electrified methane steam reformer for intensified H2 production based on conductive packed foams: experimental and modelling assessment

Production of low-carbon hydrogen is mandatory to decarbonize industrial and transportation sectors. Alongside with water electrolysis, a possible approach is represented by reducing C-emissions of H2 production processes that are already widespread and for which there is well-established know-how, like steam methane reforming (SMR). In this context, electrification (i.e. using renewable electricity to provide the heat of reaction) has gained significant industrial and academic interest in recent years. In this work, we propose a novel electrified SMR tubular reactor configuration, based on the use of resistive heating elements in tight contact with copper foams, which are packed with catalyst pellets. Thanks to the high thermal conductivity of the foams, the heat generated internally is delivered uniformly across the reactor cross section, leading to high heat transfer intensification. As already proven by our group, thermally conductive copper open-cell foams also allow for optimal heat distribution in case of conventional external heating, which paves the way for a flexible system operation that could change the source of heat supply, according to renewable energy availability. In this study, an experimental campaign is performed using a tubular reactor located inside an oven, that acts as insulation system in pure electrified tests (internal heating – IH) and mimics external heat supply of fire heated reformers (external heating – EH). The performances of the reactor are studied at atmospheric pressure, with a Gas Hourly Space Velocity of 5 Nm3/kgcat/h and a steam-to-carbon ratio of 4. The experimental results are well described by a mathematical model that, by adjusting the boundary conditions, simulates both heating modes and predicts the temperature of the resistive heating element.