Experimental and quantitative analysis of multiphase catalytic reactions under microfluidic flow conditions and geometries

Abstract

Catalytic synthesis gas and hydrogen production in coupled and decoupled compact reaction/heat exchange systems are investigated by computational and experimental techniques. Computer-based modeling and simulation studies carried out in the first phase of the research demonstrate the effects of the structural parameters of microchannel reactors on combustion-assisted conversion of C1 and C2 hydrocarbons and alcohols, and light petroleum distillates to synthesis gas/hydrogen. Outcomes of these studies set the basis for the design and construction of wall-coated catalyst integrated microchannel reactors that are used in the second part of the research involving experimental studies in which microfluidic methane-to-synthesis gas conversions via steam reforming and autothermal reforming mechanisms over Ni, Rh, Ru and Ptbased catalysts are investigated. For each catalyst, impacts of parameters such as temperature, residence time, feed compositions on methane conversion and product distribution/synthesis gas production rates are studied. The wall-coated microchannel reactor performance is also compared with that of a conventional packed-bed reactor configuration under identical conditions. The outcomes clearly show that (i) robust control of heat transfer is possible in compact reaction systems, (ii) synthesis gas production is possible with energy requirements lower than the amounts used in industrial applications, and (iii) methane conversions and synthesis gas production rates are notably higher than those obtained from a packed-bed reactor operated under identical conditions.