Steam Reforming of Methane in a Membrane Reactor: An Industrial Case Study

Techno-economic Analysis and Optimization of Intensified, Large-Scale Hydrogen Production with Membrane Reactors

Steam methane reforming (SMR) currently supplies 76% of the world's hydrogen (H2) demand, totaling ∼70 million tonnes per year. Developments in H2 production technologies are required to meet the rising demand for cleaner, less costly H2. Therefore, palladium membrane reactors (Pd-MR) have received significant attention for their ability to increase the efficiency of traditional SMR. This study performs novel economic analyses and constrained, nonlinear optimizations on an intensified SMR process with a Pd-MR. The optimization extends beyond the membrane's operation to present process set points for both the conventional and intensified H2 processes. Despite increased compressor and membrane capital costs along with electric utility costs, the SMR-MR design offers reductions in the natural gas usage and annual costs. Economic comparisons between each plant show Pd membrane costs greater than $25 000/m2 are required to break even with the conventional design for membrane lifetimes of 1-3 years. Based on the optimized SMR-MR process, this study concludes with sensitivity analyses on the design, operational, and cost parameters for the intensified SMR-MR process. Overall, with further developments of Pd membranes for increased stability and lifetime, the proposed SMR-MR design is thus profitable and suitable for intensification of H2 production.

Recent Advances in Bimetallic Catalysts for Methane Steam Reforming in Hydrogen Production: Current Trends, Challenges, and Future Prospects

As energy demand continues to rise and the global population steadily grows, there is a growing interest in exploring alternative, clean, and renewable energy sources. The search for alternatives, such as green hydrogen, as both a fuel and an industrial feedstock, is intensifying. Methane steam reforming (MSR) has long been considered a primary method for hydrogen production, despite its numerous advantages, the activity and stability of the conventional Ni catalysts are major concerns due to carbon formation and metal sintering at high temperatures, posing significant drawbacks to the process. In recent years, significant attention has been given to bimetallic catalysts as a potential solution to overcome the challenges associated with methane steam reforming. Thus, this review focuses on the recent advancements in bimetallic catalysts for hydrogen production through methane steam reforming. The review explores various aspects including reactor type, catalyst selection, and the impact of different operating parameters such as reaction temperature, pressure, feed composition, reactor configuration, and feed and sweep gas flow rates. The analysis and discussion revolve around key performance indicators such as methane conversion, hydrogen recovery, and hydrogen yield.

The Stability of a Mixed-Phase Barium Cerium Iron Oxide under Reducing Conditions in the Presence of Hydrogen

Metal oxide perovskite materials show promise for use as hydrogen separation membranes, but metal oxides can dehydrate in the presence of hydrogen to the point of decomposition. The stability of a material in the presence of hydrogen is necessary for an effective hydrogen separation membrane. The stability of a mixed phase metal oxide perovskite (BaCe_0.85Fe_0.15O_3-δ-BaCe_0.15Fe_0.85O_3-δ) was investigated using first-principles thermodynamics calculations based on density functional theory to examine the possible reduction processes on the surface of the material. It was found that for either phase of the material, the loss of H₂ becomes thermodynamically favorable over the formation of oxygen vacancies once oxygen vacancy defects exist on the surface. Additionally, both phases of the material become more stable with respect to the dehydration or loss of oxygen with increasing concentrations of surface oxygen vacancies. Under the conditions of commercial hydrogen production (~400-1100 K), it is more thermodynamically favorable for H₂ to desorb from the BaCe_0.85Fe_0.15O_3-δ phase. Examination of the atomic-scale structure indicates that the degree of coordination of surface metal atoms in this material may control the stability of the material in reducing environments.

A Review on the Different Aspects and Challenges of the Dry Reforming of Methane (DRM) Reaction

The dry reforming of methane (DRM) reaction is among the most popular catalytic reactions for the production of syngas (H₂/CO) with a H₂:CO ratio favorable for the Fischer-Tropsch reaction; this makes the DRM reaction important from an industrial perspective, as unlimited possibilities for production of valuable products are presented by the FT process. At the same time, simultaneously tackling two major contributors to the greenhouse effect (CH₄ and CO₂) is an additional contribution of the DRM reaction. The main players in the DRM arena-Ni-supported catalysts-suffer from both coking and sintering, while the activation of the two reactants (CO₂ and CH₄) through different approaches merits further exploration, opening new pathways for innovation. In this review, different families of materials are explored and discussed, ranging from metal-supported catalysts, to layered materials, to organic frameworks. DRM catalyst design criteria-such as support basicity and surface area, bimetallic active sites and promoters, and metal-support interaction-are all discussed. To evaluate the reactivity of the surface and understand the energetics of the process, density-functional theory calculations are used as a unique tool.

Heterologous Hydrogenase Overproduction Systems for Biotechnology-An Overview

Hydrogenases are complex metalloenzymes, showing tremendous potential as H2-converting redox catalysts for application in light-driven H2 production, enzymatic fuel cells and H2-driven cofactor regeneration. They catalyze the reversible oxidation of hydrogen into protons and electrons. The apo-enzymes are not active unless they are modified by a complicated post-translational maturation process that is responsible for the assembly and incorporation of the complex metal center. The catalytic center is usually easily inactivated by oxidation, and the separation and purification of the active protein is challenging. The understanding of the catalytic mechanisms progresses slowly, since the purification of the enzymes from their native hosts is often difficult, and in some case impossible. Over the past decades, only a limited number of studies report the homologous or heterologous production of high yields of hydrogenase. In this review, we emphasize recent discoveries that have greatly improved our understanding of microbial hydrogenases. We compare various heterologous hydrogenase production systems as well as in vitro hydrogenase maturation systems and discuss their perspectives for enhanced biohydrogen production. Additionally, activities of hydrogenases isolated from either recombinant organisms or in vivo/in vitro maturation approaches were systematically compared, and future perspectives for this research area are discussed.

Gas Separation Properties of Polyimide Thin Films on Ceramic Supports for High Temperature Applications

Novel selective ceramic-supported thin polyimide films produced in a single dip coating step are proposed for membrane applications at elevated temperatures. Layers of the polyimides P84^®, Matrimid 5218^®, and 6FDA-6FpDA were successfully deposited onto porous alumina supports. In order to tackle the poor compatibility between ceramic support and polymer, and to get defect-free thin films, the effect of the viscosity of the polymer solution was studied, giving the entanglement concentration (C*) for each polymer. The C* values were 3.09 wt. % for the 6FDA-6FpDA, 3.52 wt. % for Matrimid^®, and 4.30 wt. % for P84^®. A minimum polymer solution concentration necessary for defect-free film formation was found for each polymer, with the inverse order to the intrinsic viscosities (P84^® ≥ Matrimid^® >> 6FDA-6FpDA). The effect of the temperature on the permeance of prepared membranes was studied for H₂, CH₄, N₂, O₂, and CO₂. As expected, activation energy of permeance for hydrogen was higher than for CO₂, resulting in H₂/CO₂ selectivity increase with temperature. More densely packed polymers lead to materials that are more selective at elevated temperatures.

Simulation study of an auto-thermal double-membrane reactor for the simultaneous production of hydrogen and methanol: comparison of two different hydrogen redistribution strategies along the reactor

In a continuing effort to realize the simultaneous hydrogen and methanol production via the auto-thermal methanol synthesis process, the effect of two different hydrogen redistribution strategies along a double-membrane reactor has been considered. A steady-state one-dimensional heterogeneous model was developed to compare two strategies applied in the operation of the auto-thermal methanol synthesis. It was found that the counter-current configuration exhibited the better performance compared to the reactor operated in the co-current mode from both the economic and environmental points of view. This superiority is ascribed to the establishment of a more favourable temperature profile along the reactor and also more hydrogen extraction from the reaction zone. Moreover, the influence of some operating variables was investigated on the performance of the auto-thermal double-membrane reactor in the counter-current configuration. The results suggest that utilizing this configuration for pure hydrogen and methanol production could be feasible and beneficial.