Preliminary design and simulation of a microstructured reactor for production of synthesis gas by steam methane reforming

• A microstructured reactor for syngas production by methane reforming is designed.
• Reduction of channel dimensions enables operation at thermodynamic equilibrium.
• Reforming reactor can be miniaturized at constant productivity and pressure drop.
• Reduction of channel size enables to suppress heat and mass-transfer limitations.

The present study considers the potentials of the well-known production of syngas by steam methane reforming (SMR), by operation within microstructured reactors. The model of a microchannel reactor is developed, including very fast kinetic reaction rates on the coated catalytic walls of the reactor module. By varying the characteristic dimensions of the channels, and considering technical constraints on the design and operating conditions, the results demonstrate that the SMR reactor can be drastically miniaturized while maintaining its productivity without any additional pressure drop. Furthermore, by reducing the channel characteristic dimensions, it is possible to suppress heat and mass-transfer limitations enabling SMR reactor operation at thermodynamic equilibrium. A fast method for preliminary design of microstructured heat-exchanger reactors is developed, that enables to identify the optimal channels number and heat power needed to reach process specifications.