The membrane reactor system with integrated chemical reaction and membrane separation for distributed hydrogen production is of vital importance to simplify chemical process, lower energy consumption and improve techno-economics. Herein, the mathematical model were adopted to simulate methane steam reforming process in membrane reactor, and thus analyze the effect of operational strategies of permeation side, reaction pressure, reaction temperature, palladium-based membrane performance and activity of catalyst on the behaviors of membrane reactor. Subsequently, case study was conducted with the aim of maximum conversion of 1m3/h CH4 to compare membrane reactor technology and “conventional reactor + membrane separation” process. The results showed that compact design of membrane reactor under the conditions of 30atm and 500℃ can be achieved and the membrane reactor presented obvious advantages over the process technology of “conventional reactor+membrane separation”. However, more active palladium-based membranes and catalysts, particularly 10 times than current performance, were in urgent need for further process intensification. The results can provide fundamental guidelines for the design, operation and further performance intensification of membrane reactor for distributed hydrogen production with various scales. © 2022 Chemical Industry Press. All rights reserved.
