Modeling and optimization of methanol-fueled MIDREX reformers for energy-efficient hydrogen production

This study evaluates, at the reformer level only, whether methanol can replace methane as the feed to a MIDREX reformer while still delivering MIDREX-compatible syngas. We develop a three-dimensional CFD model that couples Darcy porous-flow, Maxwell–Stefan multicomponent transport, energy balance, and tube-wall thermo-mechanical stress, with global kinetics for methanol steam reforming (MSR), CO 2 dry reforming, and water–gas shift. Simulation results indicate that methanol reforming can achieve comparable or even higher syngas yields at significantly lower temperatures (approximately 500 K compared to around 1300 K for methane reforming). This reduction in operating temperature leads to nearly 60 % energy savings and lowers energy consumption from 300 to about 120 cubic meters of natural gas equivalent per ton of steel produced. Operating near 500 K reduces reformer firing duty by 60 % and therefore reformer-level CO 2 by a similar fraction, system level (life-cycle) CO 2 depends on the carbon intensity of methanol. Furthermore, the study demonstrates that shorter reformer tubes can be employed with methanol feed (up to 40 % reduction in reactor length), resulting in lower capital investment costs. The performance of various catalysts was also evaluated, with the Ni-Ga/Al 2 O 3 catalyst exhibiting superior activity and thermal stability, contributing to higher hydrogen and carbon monoxide production. Overall, this research measures the energy saved in the reformer due to methanol’s lower operating temperature. However, the total lifecycle CO 2 impact depends on how the methanol is produced. While low-carbon methanol can significantly reduce overall emissions, methanol made from fossil fuels could reduce these benefits.