Multiphysics Simulations of Dry Reforming of Methane in a Fixed Bed Reactor with Different Catalyst Types

Dry reforming of methane (DRM) uses natural gas and carbon dioxide as reactants to produce hydrogen, potentially providing a solution for reducing greenhouse gas emissions and offering an alternative carbon-free energy source. However, since DRM is highly endothermic, its application and commercialization are limited by rapid temperature decrease and resulting catalyst inactivation. Consequently, research into catalyst development and reactor design to mitigate temperature decline is essential. In this study, computational fluid dynamics (CFD) is utilized to develop a multiphysics simulation platform for DRM within a fixed-bed reactor, employing two types of spherical catalysts: eggshell and uniform types. Our findings indicate that the eggshell model can maintain a higher temperature at the reactor's core than the uniform catalyst model by approximately 20 K. Furthermore, the eggshell model demonstrates superior methane conversion and hydrogen yield due to its ability to suppress excessively rapid reactions. These results underscore the benefits of eggshell catalysts in highly endothermic reactors, such as those used in DRM processes. The developed simulation platform can be used to assess various combinations of reactor and catalyst designs and further optimize their dimensions and operational protocols.