Directly electrified SiSiC packed foam reactor for methane steam reforming: experimental study and model-based scaleup

The interest in hydrogen production is higher than ever due to its key role as carbon-free energy carrier. In this work we propose a concept of electrified Steam Methane Reforming (e-SMR) reactor where a directly Joule-heated silicon infiltrated silicon carbide (SiSiC) foam provides heat to catalytic pellets packed inside the foam openings. All the advantages associated with a pelletized catalyst are maintained while a close coupling of heat generation by the foam with heat consumption by the catalytic reaction is guaranteed. An experimental campaign demonstrated the intensification potential of the reactor, which achieved specific power inputs up to 10 MW/m3 and specific energy consumptions of 1.33 kWh/Nm3H2. A 2-D heterogeneous mathematical model was validated against the experimental data while a strategy based on sectioning the foam into several slices electrically connected in series is proposed to meet the requirements of low pressure drops and high electric circuit resistances necessary in scaled up units.