Modeling of direct Joule-heated fluidized bed steam methane reformer

• A novel computational fluid dynamics model to simulate a direct Joule-heated fluidized bed steam methane reformer. • Integrating transport phenomena, electric potential model, and reaction kinetics in the new model. • Parametric studies of the electrified reformer’s performance with the new and validated model. • Sustainable hydrogen production by a direct Joule-heated fluidized bed steam methane reformer. • Temperature control and uniform heating of direct Joule heating compared to conventional heating method. Steam methane reforming in packed bed reactors dominates global hydrogen production but suffers from poor heat transfer efficiency, non-uniform temperature distributions, and substantial carbon dioxide emissions due to fossil fuel combustion to supply the required heat. Electrification through Joule heating offers a pathway to partially decarbonize conventional steam methane reforming, while enabling distributed hydrogen production and improved process control. We hypothesized that integrating direct Joule heating with fluidized bed reactors would provide volumetric heating, minimize temperature gradient in the bed, and enhance reactor performance compared to external conventional heating methods applied to packed bed reactors. We developed a comprehensive 2D computational fluid dynamics model in ANSYS Fluent, coupling Eulerian-Eulerian multiphase hydrodynamics, electromagnetic equations, and reaction kinetics, and validated it against experimental and industrial data. Parametric studies with the validated model revealed that the direct Joule heating achieves a uniform heating with a minimal radial temperature gradient (≤5K) compared to conventional heating’s significant gradients. Although the direct Joule heating required 10 % higher energy input due to 2D geometry restricting the lateral bubble movement, the technology demonstrated rapid heating response with a potential to decrease carbon dioxide emissions by up to 50 %, positioning Joule-heated fluidized bed reformers as a promising solution for sustainable hydrogen production.