Catalytic methanol reforming process intensification for integration with proton-exchange membrane fuel cells (PEMFC) - Review

The Net Zero Scenario, driven by the imperative of carbon neutrality, demands a major reduction in reliance on fossil fuel-based hydrogen production. Another challenge is hydrogen's storage and transport due to its low volumetric energy density. These issues have elevated hydrogen carriers—particularly methanol—to a prominent position. Methanol's favorable H/C ratio, liquid state under ambient conditions, and renewable production potential establish it as a compelling hydrogen carrier. Already essential in vehicle fuels and chemical production, methanol's role is poised to expand further. Among conversion routes, methanol steam reforming (MSR) stands out for its high hydrogen yield and low CO production. This review outlines strategies for lowering the MSR reaction temperature, enabling integration with proton exchange membrane fuel cells (PEMFC), and leveraging the thermal synergy between the two systems. The review highlights the critical roles of catalysts and reactor design in optimizing MSR–PEMFC integration. A detailed evaluation of Cu-based and group 8–10 metal catalysts provides insight into their suitability for PEMFC applications. Reactor configurations, including conventional, membrane, and micro-channeled designs, are assessed for their integration potential. Finally, the review synthesizes these findings into design-oriented insights for optimizing MSR–PEMFC systems, emphasizing catalyst selection, reactor configuration, and system-level integration, offering practical pathways for implementation.