Hydrogen Production via a High-Efficiency Low-Temperature Reformer

Fuel cells are promoted by the US government as a viable alternative for clean and efficient energy generation. It is anticipated that the fuel cell market will rise if the key technical barriers can be overcome. One of them is certainly fuel processing and purification. Existing fuel reforming processes are energy intensive, extremely complicated and capital intensive; these disadvantages handicap the scale-down of existing reforming process, targeting distributed or on-board/stationary hydrogen production applications. Our project involves the bench-scale demonstration of a high-efficiency low-temperature steam reforming process. Hydrogen production can be operated at 350 to 400ºC with our invention, as opposed to >800ºC of existing reforming. In addition, our proposed process improves the start-up deficiency of conventional reforming due to its low temperature operation. The objective of this project is to demonstrate the invented process concept via a bench scale unit and verify mathematical simulation for future process optimization study. Under this project, we have performed the experimental work to determine the adsorption isotherm, reaction kinetics, and membrane permeances required to perform the process simulation based upon the mathematical model developed by us. A ceramic membrane coated with palladium thin film fabricated by us was employed in this study. The adsorption isotherm for a selected hydrotalcite adsorbent was determined experimentally. Further, the capacity loss under cyclic adsorption/desorption was confirmed to be negligible. Finally a commercial steam reforming catalyst was used to produce the reaction kinetic parameters required for the proposed operating condition. With these input parameters, a mathematical simulation was performed to predict the performance of the invented process. According to our simulation, our invented hybrid process can deliver 35 to 55% methane conversion, in comparison with the 12 and 18-21% conversion of the packed bed and an adsorptive reactor respectively. In addition CO contamination with <10 to 120 ppm is predicted for the invented process depending upon the cycle time for the PSA type operation. In comparison, the adsorption reactor can also deliver a similar CO contaminant at the low end; however, its high end reaches as high as 300 ppm based upon the simulation of our proposed operating condition. Our experimental results for the packed bed and the membrane reactor deliver 12 and 18% conversion at 400°C, approaching the conversion by the mathematical simulation. Due to the time constraint, the experimental study on the conversion of the invented process has not been complete. However, our in-house study using a similar process concept for the water gas shift reaction has demonstrated the reliability of our mathematical simulation for the invented process. In summary, we are confident that the invented process can deliver efficiently high purity hydrogen at a low temperature (~400°C). According to our projection, the invented process can further achieve 5% energy savings and ~50% capital savings over conventional reforming for fuel cell applications. The pollution abatement potential associated with the implementation of fuel cells, including the elimination of nitrogen oxides and CO, and the reduction in volatile organics and CO2, can thus be realized with the implementation of this invented process. The projected total market size for equipment sale for the proposed process in US is $1.5 billion annually