Decarbonizing Steam-Methane Reforming: Enhancing Activity through Joule Heating of a Ni/ZrO₂-Coated FeCrAl Coil

This study investigates Joule (resistive) heating as a potential method to electrify the heating process in steam-methane reforming. The significance and relevance of this research are driven by three factors: (1) increasing global demand for hydrogen as feedstock for chemical manufacturing and refining; (2) expanding hydrogen as a carbon-free energy carrier; and (3) decarbonizing the production sector of the hydrogen value chain. FeCrAl metal wire coils coated uniformly with Ni/ZrO2 catalyst were used in the Joule heating experiments. The resistive power was supplied in the range 50-90 W by varying voltage across the wire. Results show a notable, sharp increase in methane conversion at a power exceeding 60 W (750 degrees C estimated wire temperature). The results are compared with those for a conventionally-heated coated wire as well as Joule-heated uncoated ZrO2-only wires to elucidate the roles of Ni and ZrO2 and differences in the heating methods. For a range of power the methane conversion obtained with the Joule-heated Ni/ZrO2-coated wire is higher than the conventionally-heated Ni/ZrO2-coated wire. The results demonstrate that Joule heating of a catalyst-coated wire is effective for steam-methane reforming under the experimental conditions examined in our study. Underlying causes for the interesting conversion features are discussed.