Structural optimization of 3D printed SiC scaffold with gradient pore size distribution as catalyst support for methanol steam reforming

Porous ceramic catalyst supports can be used for highly efficient methanol steam reforming (MSR) due to their generally high catalyst loading capacity, large specific surface area, and high chemical stability. This paper presents a novel method to design the SiC scaffolds with optimal pore distribution as catalyst supports to enhance the hydrogen production of MSR microreactors. The structural design of the SiC scaffolds was firstly described, then numerical modeling was developed to study the flow and hydrogen production performances of the sup-ports and adopt the steepest ascent method to optimize the pore size distribution of the supports. Then, the optimized SiC supports were printed using direct ink writing of polymer-derived ceramics, then experimental tests were conducted. Both simulation and experimental results showed that the SiC supports with gradient pore size distribution can reduce the pressure drop and improve the methanol conversion rate of the microreactor. Compared with the supports with uniformly distributed pores, the pressure drops of the SiC support with gradient pore size distribution can be reduced by 2.21 % and methanol conversion increased by 13.33 % at inlet flow rate of 40 mu l/min and temperature of 280 celcius. This work demonstrated that the potential of using the proposed method to optimize the structural of the catalyst supports for the development of highly efficient MSR microreactors.