Electrified reformer for syngas production – Additive manufacturing of coated microchannel monolithic reactor

Here, an electrified reformer with a bespoke design of catalyst-coated and additively manufactured monoliths with 3-D pore architecture is presented. The 2D-pore architecture of the hexagonal honeycomb monolith was compared against the 3D-pore architecture of three broad classifications - triply periodic minimal surface (Gyroid), strut-based (Octet) and stochastic lattice (Voronoi). Gyroid structured reactor, coated with NiO/Ce_0.8Gd_0.2O_2-δ catalyst and heated to 900 °C achieved >99 % conversion of CO₂ and CH₄ at WHSV = 11,000 L.h⁻¹.kg_cat⁻¹, while remaining active for >42 h with no evidence of coke deposition. Whereas Octet and Voronoi reactors showed slightly lower conversions, with 6-fold and 4-fold higher pressure drops, respectively. This study combines Computational Fluid Dynamics and experimental evidence to reveal that the Gyroid lattice provides high catalyst deposition and catalytic activity at low pressure drops. This study demonstrates the feasibility of renewable energy-powered structured reactors to provide a pathway for low carbon footprint chemical production.