Production of Hydrogen by Methane Steam Reforming Coupled with Catalytic Combustion in Integrated Microchannel Reactors

Technological Solutions in the Field of Production and Use of Hydrogen Fuel to Increase the Thermal Efficiency of Steam Turbine TPPs

The paper discusses technological solutions in the field of production and use of hydrogen fuel, the combustion of which, in a steam-oxygen environment, can significantly increase the initial parameters of the steam turbine cycle and, thus, increase the thermal efficiency of traditional steam turbine thermal power plants. A study of technologies for the industrial production of hydrogen has been carried out. An analysis of the technical and economic features of hydrogen production technologies for use in the electric power industry showed that the most promising method is electrolysis, which makes it possible to obtain inexpensive hydrogen during hours of low demand for electricity or cogeneration of heat and electricity when electricity is a by-product. It is shown that in order to increase the power and efficiency of steam turbine TPPs, it is important to use external steam superheating from an external source of thermal energy, thus providing intermediate overheating of the working fluid by connecting an additional cycle with a higher equivalent initial temperature to the main steam turbine cycle. We have established that if we use hydrogen as a thermal energy source, the absolute efficiency of the steam turbine cycle can be increased up to 54%, taking into account the regenerative heating of feed water. In this case, at an overheating temperature equal to tпп = 760 °C, the absolute efficiency of the cycle is virtually equal to that of a CCGT unit operating at the initial gas temperature t0 = 1350 °C. At the same time, while maintaining the boiler performance, the rated capacity of the steam turbine power unit is increased by 12%. In addition, the study pays attention to the problem of increasing the power consumption of TPPs for the auxiliaries, as required to compress hydrogen and oxygen up to a pressure higher than that in the steam pipeline where the combustion chamber is installed. Our calculations have allowed us to conclude that, for the case of installing the combustion chamber in live steam, the share of additional power spent for auxiliaries should be 7%, whereas the main share of power is consumed for compressing hydrogen—94%. Despite the identified shortcomings, an economic analysis of the process of hydrogen production at TPP by electrolysis and its further use for intermediate overheating in steam turbines in order to increase their efficiency showed the effectiveness of this solution.

Recent Advances in the Development of Highly Conductive Structured Supports for the Intensification of Non-adiabatic Gas-Solid Catalytic Processes: The Methane Steam Reforming Case Study

Structured catalysts are strong candidates for the intensification of non-adiabatic gas-solid catalytic processes thanks to their superior heat and mass transfer properties combined with low pressure drops. In the past two decades, different types of substrates have been proposed, including honeycomb monoliths, open-cell foams and, more recently, periodic open cellular structures produced by additive manufacturing methods. Among others, thermally conductive metallic cellular substrates have been extensively tested in heat-transfer limited exo- or endo-thermic processes in tubular reactors, demonstrating significant potential for process intensification. The catalytic activation of these geometries is critical: on one hand, these structures can be washcoated with a thin layer of catalytic active phase, but the resulting catalyst inventory is limited. More recently, an alternative approach has been proposed, which relies on packing the cavities of the metallic matrix with catalyst pellets. In this paper, an up-to-date overview of the aforementioned topics will be provided. After a brief introduction concerning the concept of structured catalysts based on highly conductive supports, specific attention will be devoted to the most recent advances in their manufacturing and in their catalytic activation. Finally, the application to the methane steam reforming process will be presented as a relevant case study of process intensification. The results from a comparison of three different reactor layouts (i.e. conventional packed bed, washcoated copper foams and packed copper foams) will highlight the benefits for the overall reformer performance resulting from the adoption of highly conductive structured internals.

Thermodynamic Design and Performance Calculation of the Thermochemical Reformers

Thermodynamic design methods and performance calculation models for chemical reformers that can be used to recuperate exhaust heat and to improve combustion quality are investigated in this paper. The basic structure of the chemical reformer is defined as series-wound reforming units that consist of heat exchangers and cracking reactors. The CH4-steam reforming reaction is used in the chemical reformers and a universal model of this reaction is built based on the minimization of Gibbs free energy method. Comparative analyzes between the results of the calculation and a plasma-catalyzed CH4-steam reforming reaction experiment verify that this universal model is applicable and has high precision. Algorithms for simulation of series-wound reforming units are constructed and the complexity of the chemical reformers is studied. A design principle that shows the influence of structural complexity on the quantity of recovered heat and the composites of the reformed fuel can be followed for different application scenarios of chemical reformers.