Improved configuration of supported nickel catalysts in a steam reformer for effective hydrogen production from methane

The heat and mass transfer characteristics in a steam reformer are investigated via experimental and numerical approaches and a new configuration of packed catalysts is proposed for effective hydrogen production. Prior to the numerical investigation, parametric studies are carried for the furnace temperature, steam-to-carbon (S:C) ratio, and gas flow rate. After validation of the developed code, numerical work is undertaken to determine the relationship of the operating parameters. Based on the experimental and numerical results, and with the goal of obtaining optimum heat transfer characteristics and an efficient catalyst array, a new configuration for the packed bed is proposed and numerically investigated taking into account the endothermicity of the steam reforming reaction. A bed packed repeatedly with inert and active catalysts is found to be an efficient means to obtain the same, or better, hydrogen production with small amounts of the active catalysts compared with a typical steam reformer.