Improving Steam Methane Reforming Efficiency via Hierarchical Structure in Additively Manufactured Ni-Based Self-Catalytic Reactors

Hydrogen is an ideal feedstock fuel for solid oxide fuel cells (SOFCs). The steam reforming of methane (SRM) is the predominant method of producing hydrogen. However, the process of SRM relies on the involvement of a catalyst, and the reforming efficiency is constrained by the limited surface area in the traditional catalyst system. In this study, a mixer structure is applied to improve the mixing of the methane. Nano-sized pores are introduced to the struts of the mixer structure, forming a hierarchical structure, to effectively reduce the weight and increase the surface area of the self-catalytic reactors, hence increasing the catalytic efficiency. The hierarchical structure increases the reforming efficiency at all temperatures, and the level of improvement reaches its peak when the conversion rate of methane increases by 192% at 800 °C and by 40% at 900 °C compared to the self-catalyst without a hierarchical structure.