Graduate Thesis Or Dissertation
 

An investigation of the feasibility of a process-intensified differential temperature water-gas shift reactor with integrated Pt/Al2O3 catalyst

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https://ir.library.oregonstate.edu/concern/graduate_thesis_or_dissertations/z316q9113

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  • There has been serious interest in hydrogen as a source of energy in the United States due to its capability of delivering a sustainable, carbon-free energy future. Currently, most hydrogen in the United States is produced via the steam methane reforming of natural gas, which converts methane to hydrogen through a series of energy-intensive and carbon-producing reactions, one being the water-gas shift (WGS) reaction. Previous research suggests that the implementation of a differential temperature WGS reactor operating under optimal temperature conditions reduces the required reactor volume to achieve a specific CO conversion level and the hydrogen production cost associated with the overall steam reforming process. This thesis investigates the feasibility of utilizing a plate architecture WGS microreactor with integrated platinum-ceria catalyst to intensify the WGS reaction with the goal of increasing overall hydrogen yield of the steam-methane reforming process and bridging the gap towards a sustainable hydrogen future. First, modeling from previous research was used to inform the design and manufacture of a sub-scale WGS microreactor prototype. Next, a catalyst recipe for a platinum catalyst with ceria precursor supported on washcoated alumina was developed and coated onto the walls of the reaction channels in the prototype. Finally, an experimental test set-up with a reacting gas loop and integrated cooling loop was designed, constructed, and configured to enable chemical testing of the WGS reactor prototype. The WGS reactor prototype with integrated catalyst was assembled and integrated onto the test loop. The thermal behavior of the prototype was validated using inert gases, but sealing challenges arose due to the high number of mechanically sealed surfaces. The results of catalyst adhesion characterization studies suggest that enhancing the surface roughness of the substrate's surface greatly improves the adhesion of the platinum catalyst. The results of the test loop experiments suggest that difficulties in sealing plate architecture-style reactors make this type of design mechanically feasible but impractical for realizing the potential of the intensified water-gas shift reaction.
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