Design and modeling of a co-flow reactor for turquoise hydrogen production

This work focuses on the design of a reactor for producing clean hydrogen from methane pyrolysis in the form of the so-called “turquoise hydrogen”. In addition to its simple geometry, the fundamental concept and the main novelty of the proposed method rely on using part of the methane to produce the required heat needed for the thermal decomposition of methane (TDM). The reactor configuration for hydrogen production is shown to produce significant advantages in terms of greenhouse gas (GHG) emissions. A reactive flow CFD model incorporating also soot formation mechanism has been first developed and validated with experimental results available in the literature and then used to design and characterize the performances of proposed reactor configuration. 3D CFD simulations have been carried out to predict the behavior of the reactor configuration; a sensitivity analysis is used for clearing the aspect related to key environmental parameters, e.g., the global warming impact (GWI). The real potential of the proposed design resides in the low emissions and high efficiency with which hydrogen is produced at the various operating conditions (very flexible reactor), albeit subject to the presence of carbon by-product. This suggests that this type of methane conversion system could be a good substitute for the most common hydrogen production technologies.