Optimization of Small-Scale Hydrogen Production with Membrane Reactors

In the pathway towards decarbonization, hydrogen can provide valid support in different sectors, such as transportation, iron and steel industries, and domestic heating, concurrently reducing air pollution. Thanks to its versatility, hydrogen can be produced in different ways, among which steam reforming of natural gas is still the most commonly used method. Today, less than 0.7% of global hydrogen production can be considered low-carbon-emission. Among the various solutions under investigation for low-carbon hydrogen production, membrane reactor technology has the potential, especially at a small scale, to efficiently convert biogas into green hydrogen, leading to a substantial process intensification. Fluidized bed membrane reactors for autothermal reforming of biogas have reached industrial maturity. Reliable modelling support is thus necessary to develop their full potential. In this work, a mathematical model of the reactor is used to provide guidelines for their design and operations in off-design conditions. The analysis shows the influence of temperature, pressures, catalyst and steam amounts, and inlet temperature. Moreover, the influence of different membrane lengths, numbers, and pitches is investigated. From the results, guidelines are provided to properly design the geometry to obtain a set recovery factor value and hydrogen production. For a given reactor geometry and fluidization velocity, operating the reactor at 12 bar and the permeate-side pressure of 0.1 bar while increasing reactor temperature from 450 to 500 °C leads to an increase of 33% in hydrogen production and about 40% in HRF. At a reactor temperature of 500 °C, going from 8 to 20 bar inside the reactor doubled hydrogen production with a loss in recovery factor of about 16%. With the reactor at 12 bar, a vacuum pressure of 0.5 bar reduces hydrogen production by 43% and HRF by 45%. With the given catalyst, it is sufficient to have only 20% of solids filled into the reactor being catalytic particles. With the fixed operating conditions, it is worth mentioning that by adding membranes and maintaining the same spacing, it is possible to increase hydrogen production proportionally to the membrane area, maintaining the same HRF.