Modeling process intensified catalytic plate reactor for synthesis gas production

• Catalytic plate reactor model for co- and counter-flow configuration.
• Simulations using detailed surface reaction mechanism for reforming and oxidation.
• Process intensification studies to replace industrial steam reformer with catalytic plate reactor.

This paper presents numerical study of co- and counter-flow arrangements for catalytic plate reactors (CPR). CH4 steam reforming coupled with CH4 oxidation is simulated using detailed surface reaction mechanisms. Effect of inlet velocities to the reforming channel, oxidation channel, and material properties of the plate on the resulting plate temperature and CH4 conversions is studied. The simulation results agree very well with an industrial scale reformer unit and calculations are further carried out to evaluate the number of CPRs and stacks required to replace and industrial unit.