Creation of Scalable, Cartridge-Based Microreactor Reformers

Abstract : This report details the design, fabrication and testing of a new class of micro-channel reactors, combining benefits of (i) micromachining for realizing complex, two-dimensional radial distribution patterns for heat transfer and process intensification, and (ii) extrusion for versatile fabrication of scalable micro-channel networks over a range of thermal, mechanical and catalytic properties not currently achievable by current microreactor fabrication methods. This research effort resulted in the successful development of a new class of compact, cost-effective ceramic microreaders for thermal integration. The combination of materials selection and integration architecture enables unparalleled manipulation of three-dimensional thermal profiles for enhancing heat integration in microchemical systems. Experimental efforts demonstrated the ability to realize axial self-insulation with stable thermal gradients in excess of 300 degrees C, with radial thermal profiles in excess of 100 degrees C. In the absence of external insulation of any kind, hydrogen yields of 30% were achieved. Further refinements in system insulation, combustion flame mitigation and distributor designs are expected.