The microstructured reactor concept
is very promising technology
to develop a compact reformer for distributed hydrogen generation.
In this work, a catalytic plate reactor (CPR) is developed and investigated
for the coupling of methane combustion (MC) and methane steam reforming
(MSR) over Pt/Al2O3-coated microchannels in
cocurrent and counter-current modes in transient experiments during
start-up. A three-dimensional (3D) computational fluid dynamics (CFD)
simulation shows uniform velocity and pressure distribution profiles
in microchannels. For a channel velocity from 5.1 to 57.3 m/s in the
combustor, the oxidation of methane is complete and self-sustainable
without explosion, blow-off, or extinction; nevertheless, flashbacks
are observed in counter-current mode. In the reformer, the maximum
methane conversion is 84.9% in cocurrent mode, slightly higher than
that of 80.2% in counter-current mode at a residence time of 33 ms,
but at the cost of three times higher energy input in the combustor
operating at ∼1000 °C. Nitric oxide (NO) is not identified
in combustion products, but nitrous oxide (N2O) is a function
of coupling mode and forms significantly in cocurrent mode. This research
would be helpful to establish the start-up strategy and environmental
impact of compact reformers on a small scale.