Unconventional microreactor designs for process intensification in the distributed reforming of hydrocarbons: a review of recent developments at Texas A&M University

Microreactor technology promises a modular process intensification technology capable of removing heat-transfer limitations on endothermic and exothermic processes central to on-demand hydrogen production and commodity chemicals production from distributed hydrocarbon resources while providing several pathways to heat integration for these processes. Additionally, the incorporation of hydrogen-permselective membranes allows further intensification via coupling reforming or water-gas-shift catalytic processes with in situ H2 removal. The primary challenges to realizing microreactor technology for these applications remains firstly, efficient and effective thermal integration of multiple processes, secondly, realizing manufacturable designs with minimal heat-losses and/or thermal non-uniformities, and thirdly, addressing materials compatibility and durability concerns for micromembrane reactors. This brief perspectives article presents a discussion of these challenges in the context of reviewing our recent research efforts in unconventional microreactor design approaches for process intensification aimed at combining the advantages of microreactors and microfabrication with more conventional materials and fabrication techniques.