Advances in microreaction technology for portable fuel cell applications: Wall coating of thin catalytic films in microreactors

This research has focused on the need to coat microreactor systems composed of channels in the micron size range of 100 to 1000 mum. The experimental procedures and learning are outlined in terms of slurry and surface preparation requirements which are detailed in the experimental section. This system is motivated and applied to micro methanol steam reformers. Thus, a detailed discussion on the driving motivation is given in the introduction.; The low temperatures required for steam-reforming of methanol ∼ 493°K (220°C) make it possible to utilize the reformate as a feed to the fuel cell anode. The group of catalysts that shows the highest activity for methanol steam reforming (SR) at low temperature has composition of CuO/ZnO/Al 2O3, which is also the catalyst used for methanol synthesis. Steam reforming of methanol is a highly endothermic process. Conventional reactor configurations, such as a packed bed reactor, operate in a heat transfer limited mode for this reaction. Using catalyst in packed bed form for portable devices is also not convenient due to high pressure drop and possible channeling of gases in addition to poor heat transfer. A wall-coated catalyst represents a superior geometry since it provides lower pressure drop and ease of manufacturing. Due to their small size, microreactors are especially suited for endothermic reactions whose reactivity depends on the rate of heat input. A brief review on microreaction technology is given with a comprehensive survey for catalyst integration into microreactors for catalytic heterogeneous gas phase reactions.; The strength of this research is the model that was developed to coat the interior of micron sized capillaries with coats of CuO/ZnO/Al2O 3 slurries as thick as 25 mum in the dry state. The details of the model are given in terms Taylor's theory and Rayleigh's theory. A model is presented that can predict the coat thickness based on experimental conditions The model combines Taylor's experimental work with Lord Rayleigh's instability theory for annular coatings. The model presented serves as a design tool for microreactor design. The model can also estimate the maximum coat thickness possible for a given system. The results are presented in graphical format in the Microchannel Coating Model chapter.