Numerical analysis of catalytic-coated walls of an indirect internal reforming solid oxide fuel cell: Influence of catalyst coating distribution on the reformer efficiency

Highlights: • Numerical analysis on the effect of the catalyst coating design in plate reactors. • Better CH₄ conversion when the catalytic zone of the reactor is longer. • Discretizing and alternating catalytic layers give the best performances. • Inert surfaces among catalytic layers improve the thermal performances. • Good thermal performances act positively on the H₂ production. - Abstract: In this research, the performance evaluation of methane (CH₄) steam reforming in Wall Steam-methane Reformer (WCR), intended to supply hydrogen (H₂) to SOFC, is investigated using homemade code based on 2D numerical modeling. Focus is on the design of the catalyst coating on the walls of reactor. Various designs of nickel-based catalyst coating were closely examined and compared purporting to understand their effect on the WCR efficiency. The WCR designs operate at similar industrial operating conditions and with the same catalyst density. The computations were discussed with respect to the possible improvement on WCR efficiency. Comparing to the worst catalyst design found, the CH₄ conversion rate improving is estimated to 31%, which corresponds to 95.8% more in H₂ production. The obtained results are of practical importance for the design of the catalyst coating and saving fuel energy.