Parametric and sensitive analysis of Pd-Ag membrane reactor performance in biogas reforming to generate decarbonized hydrogen by Computational Fluid Dynamic-Response Surface Methodology

The efficient production of hydrogen from renewable sources is pivotal for the development of sustainable energy systems. Biogas steam reforming (BSR) conducted in palladium-based membrane reactors (MRs) offers a pathway for high-purity H2 generation at lower temperatures compared to traditional processes. In this study, a computational fluid dynamics (CFD) model was developed to simulate the BSR process within a Pd-Ag MR. The CFD model has integrated comprehensive kinetics, mass transport, and hydrodynamics, and its accuracy was confirmed through validation against experimental data, demonstrating substantial agreement. As a novel approach, to optimize the BSR reaction conditions to get the best MR performance, the CFD model was coupled with response surface methodology (RSM), which has been employed to enable the identification of optimal values for key parameters such as reaction temperature, pressure, gas hour space velocity, feed molar ratio, and sweep gas ratio, where the temperature was found to have the most significant impact on the MR’s performance within the examined intervals of input parameters. The objective of RSM method applied to CFD modeling was to maximize with high accuracy CH4 conversion, H2 recovery, and reduce CO2 emissions. RSM models effectively established correlations between input parameters and responses. The determined optimal conditions for the BSR process were a temperature of 683 K, a reaction pressure of 6 bar, a GHSV of 3000 h−1, a H2O/CH4 ratio of 1.34, and a sweep ratio of 9. Under these conditions, the system achieved remarkable results with 100 % CH4 conversion, 43 % H2 recovery, and an 81 % reduction in CO2 emissions. This study underscores the effectiveness of integrating CFD with RSM for the precise modeling and optimization of MRs in BSR reactions. The synergy between these approaches provides a robust framework for advancing the efficiency and sustainability of hydrogen production processes from renewable sources.