Enhanced catalyst stability and energy efficiency in ethanol steam reforming via induction heating

Electrifying catalytic processes through induction heating offers a transformative approach for sustainable hydrogen production by enabling rapid, localized, and energy-efficient heat delivery directly to active sites. Here, we demonstrate the enhanced catalytic performance and durability of a conventional Ni/Al 2 O 3 catalyst deposited on a FeCrAl monolith during ethanol steam reforming (ESR) under induction heating compared to conventional heating. At 435 °C, induction heating achieved a fourfold increase in hydrogen production rate (0.35 mol H 2 h −1 gcat −1 ) relative to conventional heating (0.08 mol H 2 h −1 gcat −1 ), while reducing energy consumption by 15 %. The superior stability—maintaining >90 % ethanol conversion over 28 h versus 60 % under conventional heating—is attributed to uniform temperature profiles that suppress cold-spot formation and coke-promoting side reactions. Thermodynamic analysis confirmed that induction heating preserves catalyst operation within an endothermically favorable regime, minimizing ethylene formation and carbon deposition. Post-reaction characterization corroborated a ∼30 % lower coke content and slower deactivation rate constant (1.05 × 10 −2 h −1 versus 4.14 × 10 −2 h −1 ) under induction conditions. This study provides a systematic demonstration of ethanol steam reforming driven by magnetic induction, unveiling its potential as a scalable, electrified pathway toward efficient and carbon-neutral hydrogen production. • Fourfold rise in H2 yield and 15 % lower energy use vs. conventional heating. • Maintains >90 % ethanol conversion over 28 h with minimal coke formation. • Uniform, localized heating enhances catalyst activity and stability. • Demonstrates scalable, electrified route to carbon-neutral H2 production.