Design of Modular Methanol Reformers Utilizing Industrial Waste Heat for Sustainable Hydrogen Production

Renewable methanol is considered a promising carrier for sustainable hydrogen due to its convenience in storage and transportation. Methanol steam reforming (MSR) using exhaust heat from industrial boilers can further enhance energy efficiency. However, existing methanol reforming systems still face challenges in terms of matching with industrial boilers, heat exchanger compactness, and adaptability to fluctuations in exhaust gas conditions. To address these issues, this study proposes the design of a modular methanol reforming system driven by the exhaust heat of small industrial boilers and develops a three-dimensional multiphysics simulation model to investigate the heat transfer and reaction characteristics within the reactor. The results indicate that, within the ranges of exhaust heat temperature (220–270 °C), flow rate (0.4–1.2 g/s), and channel spacing (60–100 mm), increasing the exhaust heat temperature enhances the endothermic reforming process, while decreasing the channel spacing improves heat transfer and increases methanol conversion. The reactor with a 60 mm channel spacing achieves a conversion ratio of up to 95.3% at a flow rate of 0.4 g/s. Although the hydrogen yield increases with flow rate, the single-pass conversion ratio decreases due to shorter residence time and increased load per unit volume. Compared to traditional fixed-structure reactors, the proposed modular system allows flexible matching of scale and heat exchange capacity through adjustable channel configurations, enhancing adaptability to fluctuations in industrial exhaust temperature and load. This design improves the utilization efficiency of low-grade waste heat and offers a practical engineering solution for sustainable distributed hydrogen production.