Transport-reaction-permeation regimes in catalytic membrane reactors for hydrogen production. The steam reforming of methane as a case study

Toward Minimal Complexity Models of Membrane Reactors for Hydrogen Production

Membrane reactors are inherently two-dimensional systems that require complex models for an accurate description of the different transport phenomena involved. However, when their performance is limited by mass transport within the reactor rather than by the selective product permeation across the membrane, the 2D model may be significantly simplified. Here we extend results previously found for methane steam reforming membrane reactors to show that such simplified two-dimensional model admits either a straightforward analytical solution for the cross-section averaged concentration profile, or can be reduced to a 1D model with an enhanced Sherwood number, depending on the stoichiometry of the reaction considered. Interestingly, the stoichiometry does not affect the expression of the enhanced Sherwood number, indicating that a versatile tool has been developed for the determination of membrane reactor performance at an extremely low computational cost and good degree of accuracy.

A CFD study on the performance of CO2 methanation in a water-permeable membrane reactor system

A water-permeable membrane reactor is proposed to promote CO2 methanation with in situ removal of H2O. A two-dimensional CFD simulation model is built up and the effects of GHSV, H2O permeance and CO2/H2 permeation selectivity are investigated.

An Enhanced Sherwood Number to Model the Hydrogen Transport in Membrane Steam Reformers

It is well known that membrane reactors are inherently two-dimensional systems in which species concentrations vary as a consequence of both the reaction and permeation across the membrane, which occurs in the direction perpendicular to that of the main gas flow. Recently, an expression for an enhanced Sherwood number was developed to describe the hydrogen concentration gradients arising in methane steam-reforming membrane reactors as a consequence of the combined effect of hydrogen production, dispersion, and permeation. Here, the analysis is developed in further detail with the aim of (i) assessing the validity of the simplifying assumptions made when developing the 1D model and (ii) identifying the operating conditions under which it is possible to employ the 1D model with the enhanced Sherwood number.

Hydrogen Production via Steam Reforming: A Critical Analysis of MR and RMM Technologies

‘Hydrogen as the energy carrier of the future’ has been a topic discussed for decades and is today the subject of a new revival, especially driven by the investments in renewable electricity and the technological efforts done by high-developed industrial powers, such as Northern Europe and Japan. Although hydrogen production from renewable resources is still limited to small scale, local solutions, and R&D projects; steam reforming (SR) of natural gas at industrial scale is the cheapest and most used technology and generates around 8 kg CO₂ per kg H₂. This paper is focused on the process optimization and decarbonization of H₂ production from fossil fuels to promote more efficient approaches based on membrane separation. In this work, two emerging configurations have been compared from the numerical point of view: the membrane reactor (MR) and the reformer and membrane module (RMM), proposed and tested by this research group. The rate of hydrogen production by SR has been calculated according to other literature works, a one-dimensional model has been developed for mass, heat, and momentum balances. For the membrane modules, the rate of hydrogen permeation has been estimated according to mass transfer correlation previously reported by this research group and based on previous experimental tests carried on in the first RMM Pilot Plant. The methane conversion, carbon dioxide yield, temperature, and pressure profile are compared for each configuration: SR, MR, and RMM. By decoupling the reaction and separation section, such as in the RMM, the overall methane conversion can be increased of about 30% improving the efficiency of the system.

Integrated Design and Control of Various Hydrogen Production Flowsheet Configurations via Membrane Based Methane Steam Reforming

This work focuses on the development and implementation of an integrated process design and control framework for a membrane-based hydrogen production system based on low temperature methane steam reforming. Several alternative flowsheet configurations consisted of either integrated membrane reactor modules or successive reactor and membrane separation modules are designed and assessed by considering economic and controller dynamic performance criteria simultaneously. The design problem is expressed as a non-linear dynamic optimization problem incorporating a nonlinear dynamic model for the process system and a linear model predictive controller aiming to maintain the process targets despite the effect of disturbances. The large dimensionality of the disturbance space is effectively addressed by focusing on disturbances along the direction that causes the maximum process variability revealed by the analysis of local sensitivity information for the process system. Design results from a multi-objective optimization study, where only the annualized equipment and operational costs are minimized, are used as reference case in order to evaluate the proposed design framework. Optimization results demonstrate the controller’s ability to track the imposed setpoint changes and alleviate the effects of multiple simultaneous disturbances. Also, significant economic improvements are observed by the implementation of the integrated design and control framework compared to the traditional design methodology, where process and controller design are performed sequentially.

Mass Transfer Coefficient in Multi-Stage Reformer/Membrane Modules for Hydrogen Production

Hydrogen is a promising energy carrier, and is exploitable to extract energy from fossil fuels, biomasses, and intermittent renewable energy sources and its generation from fossil fuels, with CO₂ separation at the source being one of the most promising pathways for fossil fuels' utilization. This work focuses on a particular configuration called the Reformer and Membrane Module (RMM), which alternates between stages of Steam Reforming (SR) reactions with H₂ separation stages to overcome the thermodynamic limit of the conventional SR. The configuration has numerous advantages with respect to the more widely studied and tested membrane reactors, and has been tested during a pilot-scale research project. Although numerous modelling works appeared in the literature, the design features of the material exchanger (in the so-called RMM architecture) of different geometrical configurations have not been developed, and the mass transfer correlations, capable of providing design tools useful for such membrane modules, are not available. The purpose of this work is therefore to apply a physical-mathematical model of the mass transfer, in three different geometries, considering both concentration polarization and membrane permeation, in order to: (i) simulate the cited experimental results; (ii) estimate the scaling-up correlations for the "material exchange modules"; and (iii) identify the mass transfer limiting regime in relation to the gas mass flow rate.

Modeling Fixed Bed Membrane Reactors for Hydrogen Production through Steam Reforming Reactions: A Critical Analysis

Membrane reactors for hydrogen production have been extensively studied in the past years due to the interest in developing systems that are adequate for the decentralized production of high-purity hydrogen. Research in this field has been both experimental and theoretical. The aim of this work is two-fold. On the one hand, modeling work on membrane reactors that has been carried out in the past is presented and discussed, along with the constitutive equations used to describe the different phenomena characterizing the behavior of the system. On the other hand, an attempt is made to shed some light on the meaning and usefulness of models developed with different degrees of complexity. The motivation has been that, given the different ways and degrees in which transport models can be simplified, the process is not always straightforward and, in some cases, leads to conceptual inconsistencies that are not easily identifiable or identified.