Membrane Reformer Hydrogen Production Efficiency

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Solution Overview

Problem

Conventional steam methane reforming for hydrogen production is inefficient, particularly at small scales, due to high energy consumption and carbon dioxide emissions, and lacks effective CO2 capture and utilization.

Innovation Solution

A membrane reformer system that uses a hydrogen-selective membrane to separate and purify hydrogen during the steam reforming process, allowing for lower operating temperatures and integrated CO2 capture, with electrical heating and a dry reforming catalyst to enhance efficiency and reduce carbon formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional steam reforming is used to produce hydrogen, then hydrogen can be produced from natural gas, but energy consumption is high and carbon dioxide emissions increase

Engineering Contradiction:

Improvehydrogen production efficiencyVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The reforming process is divided into two stages: pre-reforming at lower temperature to convert hydrocarbons to methane, followed by steam reforming of methane. This segmentation allows each stage to operate under optimized conditions, reducing overall energy consumption while maintaining high hydrogen production efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the temperature parameter profile across the reactor, operating the pre-reforming section at lower temperature (700-900°C) compared to conventional single-stage reforming (900-1100°C). This parameter change reduces energy consumption while the membrane separation maintains high hydrogen yield

Inventive Principle:

Principle #35Parameter changes

2Productivity

If conventional steam reforming is used, then hydrogen production can proceed, but carbon dioxide emissions are not captured

Engineering Contradiction:

Improvehydrogen productionVSAvoidcarbon dioxide emissions

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

A hydrogen-selective membrane is introduced to extract and separate hydrogen from the reformate stream as it is produced. This extraction shifts the reforming equilibrium toward complete conversion, increasing hydrogen yield while concentrating CO2 in the retentate stream for easier capture and utilization

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention converts the harmful CO2 byproduct into a useful resource by concentrating it in the retentate stream through membrane separation. The CO2 can then be captured and utilized for various applications such as enhanced oil recovery, chemical synthesis, or carbonation processes, transforming an environmental liability into an asset

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Adaptability or versatility

If small-scale hydrogen production is implemented using conventional methods, then local hydrogen supply is possible, but energy consumption per unit increases

Engineering Contradiction:

Improvesmall-scale production capabilityVSAvoidenergy consumption per unit

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The pre-reforming and steam reforming processes are merged into a single integrated reactor with a membrane separator. This combination eliminates the need for separate high-temperature reforming equipment, reducing capital costs and energy consumption while enabling efficient small-scale hydrogen production

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention operates at moderately elevated temperatures (700-900°C) rather than the very high temperatures required by conventional reforming, reducing the energy input per unit of hydrogen produced. This parameter change makes small-scale production economically viable while maintaining efficiency

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The membrane reformer system increases hydrogen yield and purity, reduces energy consumption, and enables efficient CO2 capture and utilization, making it suitable for small-scale hydrogen production while minimizing environmental impact.

Implementation Method 1

converting hydrocarbon to methane via the pre-reforming catalyst in the pre-reformer

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

converting methane in the pre-reformed intermediate to hydrogen and carbon dioxide by steam reforming via the reforming catalyst

Methodology Applied

Scientific EffectEndothermic Reaction: Endothermic Reaction

Implementation Method 3

diffusing the hydrogen from the region through the tubular membrane (hydrogen selective) into a bore of the tubular membrane

Methodology Applied

Scientific EffectPermeation: Permeation

Data Source

PatentUS11492254B2Hydrogen production with membrane reformer

Publication Date: 2022.11.08 SAUDI ARABIAN OIL CO

AI summary

A system and method of producing hydrogen, including converting hydrocarbon to methane via steam and pre-reforming catalyst in a pre-reformer, converting the methane to hydrogen and carbon dioxide by steam reforming via a reforming catalyst in a membrane reformer, diffusing through hydrogen through a tubular membrane in the membrane reformer.