The implementation of fuel cell deployment requires efficient conversion of fuels into hydrogen in a distributed energy system. Fortunately, continuous flow and microreactor technology provide unique opportunities for the portable production of hydrogen. This study focuses on determining the operation space for a thermally integrated methane reforming system, thereby providing a theoretical basis for the design and optimization of such systems. The steam-methane reforming over rhodium coupled with methane combustion over platinum in a thermally integrated microchannel reactor arranged with rectangular-shaped protuberances was studied numerically in order to improve its operability and stability. Computational fluid dynamic simulations were carried out with detailed reaction mechanisms to identify conditions for the maximum hydrogen yield and the highest output power. Various operating lines were presented, and various performance metrics were evaluated accordingly. The results indicated that the efficient production of hydrogen is made possible through improving transport performance for highly active catalysts. The flow disturbance elements designed for the reactor are of great benefit to intensification of the reforming process. There exists a trade-off between fuel utilization and output power. Autothermal operation advantages from improved transport performance in small physical dimensions were demonstrated for the system, but careful thermal management is always necessary to ensure its efficient and stable operation. The thermal conductivity of the wall separating the exothermic and endothermic reactions plays a significant role in determining the performance of the system. Highly active catalysts are required to intensify the overall reforming process and to achieve efficient thermal management. Adjustment of fluid velocities can serve as a convenient means to achieve efficient operation of the system.
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