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A comparison study on methanol reforming catalysts for on-
board hydrogen generation
Yanjing Su1a*, Jiao Yu1b*, Jianyue Shen2c*
1 Suzhou Qingjie Power Technology Co., Ltd, SuZhou200240, China
2 Shanghai Palcan New Energy Technology Co., Ltd, Shanghai201108, China
Abstract—In hydrogen energy applications, methanol is the best fuel that can effectively solve the problem
of the storage and transportation of hydrogen. The lowest reforming temperature among hydrocarbons also
makes it the best fuel for hydrogen generation. This paper aimed to study and compare four methanol-
reforming catalysts and screen the best one suitable for the on-board hydrogen generation system. In this
study, the in-house single-tube reactor, which can precisely control the temperature by a multistage heater,
was applied to study the catalyst performance. Physical and chemical properties of the catalyst, such as
methanol conversion rate, hydrogen generation rate, CO selectivity at a different liquid hourly space
velocity (LHSV), catalyst density, and optimum reaction temperature, were also systematically studied. The
hydrogen generation rate per unit mass of the WEF catalyst is the highest, which reached 0.122 g/h·gcat in
9.23 h-1 LHSV. And the methanol conversion rate in 7.72 h-1 LHSV is 96.74%, and somewhat below the
BSF catalyst (97.90% in 7.55 h-1 LHSV). The study indicated that the catalyst made by WEF is the best
catalyst for on-board hydrogen generation when comprehensively considering the requirement including the
performance and vibration resistance. At the end of this paper, the optimized direction of the four catalyzers
is also specified.
reforming has attracted much attention because of its
1. Introduction higher efficiency and lower energy consumption [7]. The
existence of the catalyst for methanol steam reforming
Hydrogen is considered an environmentally friendly makes the reaction pathway change, thus reducing the
energy source due to its carbon-free properties. However, activation energy of the reaction and speeding up the
hydrogen has much less volume energy density (Wh/L) chemical reaction. The commonly used MSR reaction
than other fuels (it is much less dense than other catalysts mainly include copper-based and group VIII
hydrocarbon and alcohol fuels under standard metal-based catalyzers [8].
temperature and pressure conditions). There are still Copper-based catalysts are more conducive to
many problems to solve in high-pressure storage, low- generating H2 and CO2 than most group VIII-X metallic
temperature liquid storage, compound storage, and other element catalysts [9]. But there are still many problems in
methods [1-2], which caused many difficulties in the copper catalysts resulting in the degradation of
practical application of hydrogen. Therefore, by performance, such as being more likely to suffer
reforming natural gas, ethanol, methanol, dimethyl ether, sintering, being more sensitive to sulfur and oxygen, and
gasoline, diesel, and so on into hydrogen-rich gas, the having much easier spontaneous combustion [6]. Adding
realization of online generation and use of hydrogen has auxiliaries can improve the stability of the copper-based
gotten much attention. catalyst, and the most commonly used auxiliaries are
As a hydrocarbon with only one carbon atom, ZnO, ZrO2, CeO2, Al2O3, etc. The catalyst with a spinel
methanol has the highest hydrogen-carbon ratio among structure has also proven effective in improving the
the fuels that can generate hydrogen by the reforming reforming performance [6]. Fasanya et al. [10] reported the
reaction. Also, because of the lack of C=C bond [3], it performance of a nanostructured Cu-Zn catalyst with an
could convert into hydrogen gas at low temperatures alcohol-water ratio of 0.8. No CO was generated when
(200 ℃~300 ℃), which has considerable advantages the catalyst was tested at 180 ℃~230 ℃, indicating its
over other hydrocarbons (such as methane: conversion potential in low CO application. Zhao et al. [11]
temperature 800 ℃~1000 ℃ [4]; ethanol: the conversion investigate the Ti-modified Cu/γ-Al2O3/Al catalyst
temperature is more than 600 ℃ [5]). prepared by the anodic oxidation method. The addition
The route of methanol-reforming nowadays is of Ti improved the dispersion of copper and increased
divided into four ways: Methanol Steam Reforming the adsorption capacity of water and methanol. The co-
(MSR), Partial Oxidation of Methanol (POM), existence of Ti4+ and Ti3+ also improves the redox
Autothermal Reforming of Methanol (ATRM), and properties of copper. When formulated as CuTi1.9/γ-
Methanol Decomposition (MD) [6]. Methanol steam Al2O3/Al, the methanol conversion rate reached 100%.
a*yanjing_su@[Link], b*[Link]@[Link], c*jshen@[Link]
© The Authors, published by EDP Sciences. This is an open access article distributed under the terms of the Creative Commons Attribution
License 4.0 ([Link]
E3S Web of Conferences 385, 02011 (2023) [Link]
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Chen et al. [12] developed a Cu-Zr component catalyst Through the systematic analysis of the density of each
with Attapulgite-based Zeolite (AZ) as the support for catalyst, the optimal working temperature, reforming
the MSR reaction. The MSR activity tests showed that performance, and other parameters, it is found that the
the microporous and mesoporous channels synthesized in WEF type of platinum-based methanol reforming
AZ could improve the catalytic performance by catalyst based on FeCrAl wire carrier is relatively more
promoting heat and mass transfer. Zr Addition suitable for the use of the vehicle-mounted methanol-
significantly increased the distribution of active metal reforming system. At the same time, the paper puts
particles and the metal surface area and also promoted forward the direction of further improvement for the four
the formation of Cu0/Cu+-ZrOxHy interface sites. The kinds of catalysts. The results laid a foundation for
synergistic effect above can inhibit the sintering and vehicle-mounted methanol reforming catalysts and
carbon deposition of active metals and promote the systems.
oxidation of intermediate products and the water vapor
transformation reaction.
Pt and Pd-based catalysts are studied extensively 2. Experimental
among Group VIII metal-based catalysts. Compared with
copper-based catalysts, they have excellent thermal 2.1 Experimental Instrument
stability, so there are fewer effects of being sintered (the
most fundamental reason for performance attenuation). The Steam Reformer (STR) used in this experiment has
However, these catalysts require a higher operating several heating rings, and it can control the temperature
temperature, and then the higher content of CO in the by multistage heating. Due to the order, the carrier
reforming gas was unavoidable. ZnO, ZrO2, CeO2, and (catalyst) close to the inlet may catalyze more methanol-
Al2O3 also be commonly used for modifying group VIII water steam, resulting in a temperature difference
metal-based catalysts [6,8]. Liu etc. [13] reported a PdZnβ between the different sites in the STR tube. The design
alloy catalyst load on ZnAl2O4 with an excellent CO2 of the STR can solve the problem dexterously, and the
selectivity when palladium content is 1000ppm (97%). single-tube reactor model is shown in Fig. 1(a).
Kim et al. [14] find that Ru doping in Pd/Al2O3 can Fig. 1(b) shows the arrangement of temperature
promote the methanol steam reforming reactions. sensors inside the reactor. To accurately monitor the
Compared with Pd/Al2O3, adding Ru in Pd/Ru/Al2O3 can temperature, eight sensors are placed in the reforming
effectively improve its catalytic capacity. Further study tube at a certain distance apart. Red points indicate the
showed that the main reason for the improvement was temperature sensor placed in the center of the core, and
that the formation of Pd-Ru alloy reduced the size of Pd blue indicates the temperature sensor placed in the inner
particles, which further improved the dispersion of Pd in wall of the tube. At the same time, to make the methanol-
the catalyst. water vapor entering the catalyst reach the set
In this paper, two types of commercialized copper- temperature, four FeCrAl wire clusters were placed at the
based catalyzers (BSF and CLN), a platinum-based entrance of the reaction tube to promote the further
catalyst (WEF) and a self-developed copper-based temperature rise of the methanol-water vapor.
catalyst (JSU), were systematically studied based on the Besides the single tube reformer, there are electronic
application of vehicle catalysts for methanol-reforming. scales, methanol storage tanks, peristaltic pumps,
Considering the onboard reforming system used for evaporator (EVA), condensers, soap film flowmeters,
hydrogen generation, the catalyst inside should be dryers, bubblers, gas chromatography (GC), etc. in the
lightweight, energy-saving, and have better shock reforming system. The specific models of the relevant
resistance to withstand a harsher working environment. experimental instruments are shown in Table 1.
(a) (b)
(a) Model of the single-tube reactor (b) The arrangement of temperature sensors
Fig. 1 The steam reformer
Table 1 The experimental instruments of the test system
Equipment Version Manufacturers
1 Electronic Scales JNS-6HWC Hengzhifu Technology
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2 Peristaltic Pump BR100 Zibo Niukai
3 EVA & STR / Self-Innovate
5 Condenser 2000 mL Lei Gu Technology
6 Soap Film Flowmeters JCL-2010(S)-F Qingdao Juchuang
7 GC 490 Micro GC Agilent Technologies
8 Spring heater 30*50/K OYG
9 Sheathed Thermocouple KPS-IN600-ZG1/B Kaipusen
The flow chart of the experiment is shown in Fig. 2. measure reformed gas flow rate with soap film
The experimental process is as follows: (1) heating the flowmeters, (6) test the composition of reformed gas by
EVA and the STR, (2) pumping the methanol in the GC, (7) test condensate composition by GC. The mass
reactor with a peristaltic pump, (3) the methanol-water fraction of the methanol aqueous solution used in the
solution evaporates in the EVA and then reforming in experiment is 54.3%.
STR, (4) condense the reforming gas in the condenser, (5)
Fig. 2 The flow chart of the experiment
graininess catalysts with CuO as the active constituent.
2.2 Catalyst and Principle Make ZnO the auxiliary agent and Al2O3 the support.
Several materials are mixed and then pressed and
The main ingredient of the four different catalysts tested
sintered into catalyst particles. The active ingredient of
in this experiment is shown in Table 2. The WEF catalyst
the JSU catalyst is CuO, and the auxiliary agent is ZrO2.
is a platinum-based catalyst that uses In2O3 as an
The catalyst is attached to the Al2O3 ball by
auxiliary agent. The catalyzer is coated on the FeCrAl
impregnation method inside the channel.
filament clusters. The BSF and CLN catalysts are
Table 2 Information on the catalysts
Active Accessory
Catalyst Carrier
Ingredients Ingredient
WEF Pt In2O3 FeCrAl Wire
BSF CuO ZnO Al2O3 Powder
CLN CuO ZnO Al2O3 Powder
JSU CuO ZrO2 Al2O3 Ball
All the catalysts for hydrogen generation of Methanol Steam Reforming Reaction (MSR):
methanol-reforming studied in this paper are methanol CH3OH+H2O→CO2+3H2 Δ0298 =+49.4
steam reforming catalysts. Due to the intermediates in
the methanol reaction process, the reaction is kJ/mol (1)
complicated. The study on the mechanism of methanol Methanol Decomposition Reaction (MD):
steam reforming has not reached a consensus. At present, CH3OH→CO+2H2 Δ0298 =+92.0
the conclusion of the stream reaction mechanism is kJ/mol (2)
mainly five kinds. They are the methanol decomposition- Water Gas Shift Reaction (WGS):
water gas shift mechanism, methanol steam reforming-
methanol decomposition mechanism, methanol steam CO+H2O→CO2+H2 Δ0298 =-41.4
reforming-water gas replacement inverse transformation kJ/mol (3)
mechanism, methanol steam reforming-decomposition- Equation (1) methanol steam reforming reaction and
water gas shift mechanism, and reaction mechanism equation (2) methanol decomposition reaction is an
containing intermediate products. Taking the methanol endothermic reaction, and equation (3) water gas shift
steam reforming-decomposition-water gas shift reaction is an exothermic reaction. When methanol is
mechanism as an example. The reaction mainly includes 100% converted into hydrogen, equation (1) can also be
the following three processes: regarded as the total reaction formula of methanol steam
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reforming reaction, and the whole reaction is confirm the parameters before the study. Firstly, the
endothermic [15-16]. molar ratio of water to methanol is fixed as 1.5
(methanol aqueous solution with 54.3% mass
concentration) based on previous experience. Then fix an
2.3 Catalysts characterization
appropriate LHSV, test the catalyst at different
In this paper, the evaluation index of the performance of temperatures, and obtain the optimum reaction
the catalysts is as follows: LHSV (h-1) - the ratio of the temperature. Finally, analyze the performance of each
volume of methanol-water injected per hour to the total catalyst under the optimum reaction temperature and
volume of catalyst; methanol conversion rate (%) - the different LHSVs.
proportion of the amount of methanol consumed by the
reaction to the total amount of methanol injected; 3. Test Results and Discussion
hydrogen generation rate per unit volume Catalyst
(g/h·cm3cat) - the ratio of the mass of hydrogen generated
per hour to the total catalyst volume; Catalyst hydrogen 3.1. Bulk Density of the catalyst
generation rate per unit mass (g/h·gcat) - the ratio of the
mass of hydrogen generated per hour to the total catalyst Fig. 3 shows the bulk density of the four catalysts. CLN
mass; CO selectivity (%) - the molar amount of CO in catalyst has the highest density, which is 1.601 g/cm3.
dry gas versus the molar amount of CO+CO2; bulk The bulk density of the WEF catalyst is 0.799 g/cm3,
density of the catalysts (g/cm3) - density obtained by which is the minimum. The bulk density of the catalyst
dividing catalyst mass by the volume of the container can affect the volume and weight of the reformer. If the
occupied by the catalyst. performance is consistent at the same LHSV, the
Many factors may affect the methanol-reforming catalyzer with a smaller bulk density is more dominant.
reaction, including water-alcohol ratio, reaction
temperature, LHSV, catalyst type, etc. So, we should
Fig. 3 Bulk densitiy of different catalyst
the average contact time between reactant and catalyst
3.2. Methanol conversion rate decreases, leading to a decrease in conversion rate. The
catalyst with the highest methanol conversion rate was
After a series of tests, the optimized reaction temperature
the BSF catalyst (95.38% in 8.6 h-1 LHSV, 97.90% in
of the catalysts was confirmed. The optimal reaction
7.55 h-1 LHSV), followed by the WEF, CLN, and JSU
temperature range of the WEF catalyst was 325~375 ℃.
catalysts. The methanol conversion rate of the WEF
The optimal reaction temperature range of the BSF, CLN, catalyst in 9.23 h-1 LHSV is 91.83%, and 96.74% in 7.72
and JSU catalysts was 225~285 ℃. And the following h-1 LHSV. CLN catalyst at an LHSV of 8.79 h-1 has a
study was tested under the same conditions. Fig. 4 shows methanol conversion rate of 82.87%. The methanol
the methanol conversion rate of four catalysts at different conversion rate for the JSU catalyst at an LHSV of 6.21
LHSVs. First, the methanol conversion rate decreases h-1 is 59.64 %.
with the increase of LHSV. The main reason is that the
increasing reactant increases the airspeed in the tube, and
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Fig.4 Methanol conversion rate at different LHSV
g/h·cm3cat. The JSU catalyst has the lowest catalytic
3.3. Hydrogen generation rate performance. At LHSV of 6.21 h-1, the hydrogen
generation rate is 0.328 g/h·cm3cat.
Fig. 5(a) shows the hydrogen generation rates based on
The study aimed at studying the methanol-reforming
different LHSVs. Firstly, with the increase of LHSV, the
catalysts applied onboard. So, the weight of the catalyst
hydrogen generation rate of the catalyst increases. The
is also a consideration. The hydrogen generation capacity
chemical reaction moves in forward because of the
of the catalyst per unit mass under different LHSVs is
addition of reactants. Moreover, the LHSV in the test has
shown in Fig. 5(b). As seen from the figure, the WEF
not reached the maximum reactivity of the catalyst. As
catalyst has the highest hydrogen generation capacity per
may be seen from the diagram, the BSF and WEF
unit mass catalyst. The hydrogen generation rate of the
catalysts have the highest hydrogen generation capacity.
catalyzers at 9.23 h-1 is 0.122 g/h·gcat. The BSF, JSU, and
At an LHSV of 4~7 h , the capacity of hydrogen
-1
CLN catalysts decreased. The changed phenomenon
generation for the BSF catalyst is slightly higher than
concerning the hydrogen generation per unit volume of
that of the WEF catalyst. At an LHSV within 7~9 h , the
-1
catalysts, mainly because the density of catalysts was
hydrogen generation capacity of the BSF and WEF
quite different. At LHSV of 8.60 h-1, the hydrogen
catalyst is almost the same. The hydrogen generation
generation rate of the BSF catalyst per unit mass is 0.067
capacity of CLN and JSU catalysts ranked third and
g/h·gcat. At LHSV of 6.21 h-1, JSU has a performance of
fourth. At an LHSV of 8.60 h-1, the hydrogen generation
0.042 g/h·gcat. The hydrogen generation rate of the CLN
rate of the BSF catalyst is 0.755 g/h·cm3cat. The hydrogen
catalyst at LHSV 8.79 h-1 is 0.050 g/h·gcat.
generation rate of the WEF catalyst at LHSV 9.23 h is -1
0.779 g/h·cm3cat. CLN catalyst at LHSV 8.79 h-1 is 0.637
(a) (b)
(a) Based on per unit volume of catalyst (b) Based on per unit mass of catalyst
Fig. 5 Hydrogen generation rate of four catalysts at different LHSVs
average temperature is taken and recorded in the data
3.4. CO Selectivity chart. The CO content in the dry gas of the WEF catalyst
is the highest. Under the working temperature of 330 ℃,
FIG. 8 shows the gas components of reformed gas
the average CO content in the dry gas at different LHSVs
generated by different catalysts at different LHSVs. Fig.
is 4.61% and the average CO selectivity is 4.38%. The
8(a) shows the CO content in reformed dry gas
CO content of the BSF, CLN, and JSU catalysts
(excluding methanol and water), and Fig. 8(b) shows the
decreased successively, and the CO selectivity has a
CO selectivity. The reaction temperature has a significant
similar pattern. The average working temperature with
effect on the content of CO in the reforming gas. The
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CO content and CO selectivity of the BSF, CLN, and of the reforming reaction. Because there is a WSG
JSU catalysts were 255℃ - 2.28% - 4.18%, 285℃ - 1.64% process in the methanol steam reforming reaction, this
- 3.54%, and 275℃ - 0.76% -2.67%, respectively. The reaction is exothermic. When the temperature rises, the
main reason for the difference in CO content and CO chemical balance moves in the opposite direction,
selectivity in reforming gas is the temperature difference resulting in the rise of CO content.
(a) (b)
(a) CO content at a different LHSV (b) CO selectivity at a different LHSV
Fig. 6 Components of the dry reforming gas
platinum-based catalysts and then develop low-
4. Conclusion temperature noble metal catalysts, thus reducing the
difficulty of application in mobile devices. As well as
This study compared the physicochemical properties and reduce the concentration of CO in the reformed gas and
the catalytic performance of four catalysts. Based on the expand their application; (2) improve the durability of
results and discussions presented above, the conclusions copper-based catalysts and develop methanol reforming
are obtained as below: catalysts with high hardness, durability, and catalytic
(1) The hydrogen generation rate per unit mass of activity.
the WEF catalyst is the highest. The hydrogen generation
rate of the catalyzers in 9.23 h-1 is 0.122 g/h·gcat, which
can better meet the lightweight requirements of mobile Acknowledgments
devices. The methanol conversion rate is 91.83% in this
condition. And the methanol conversion rate can reach This work was financially supported by the Shanghai
96.74% in 7.72 h LHSV. At the same time, the WEF
-1 Science and Technology Commission's "Science and
catalyst is coated on the FeCrAl filament clusters. So, its Technology Innovation Action Plan" high-tech field
vibration resistance is excellent. Meanwhile, it has some project (19511108200) and the 2021 Innovative and
disadvantages: the operating temperature is too high, and Entrepreneurial Talent Project of Jiangsu Province
the CO content is almost twice as much as copper-based (JSSCRC2021330).
catalysts. The features make it more suitable for use in
hydrogen combustion engines. References
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