How gas flow design can influence the performance of a DBD plasma reactor for dry reforming of methane

•A novel DBD reactor for testing gas mixing of multi-component mixtures is designed.•Gas flow orientation within fixed parameters and reactor size affects the performance.•The reaction zone size, flow rate, and power delivery have specific interactions.•Gas mixing by gradual or separate addition can tune individual product conversion.•Pre-activation of the individual gasses offers little improvement. DBD plasma reactors are commonly used in a static ‘one inlet – one outlet’ design that goes against reactor design principles for multi-component reactions, such as dry reforming of methane (DRM). Therefore, in this paper we have developed a novel reactor design, and investigated how the shape and size of the reaction zone, as well as gradual gas addition, and the method of mixing CO2 and CH4 can influence the conversion and product composition of DRM. Even in the standard ‘one inlet – one outlet’ design, the direction of the gas flow (i.e. short or long path through the reactor, which defines the gas velocity at fixed residence time), as well as the dimensions of the reaction zone and the power delivery to the reactor, largely affect the performance. Using gradual gas addition and separate plasma activation zones for the individual gases give increased conversions within the same operational parameters, by optimising mixing ratios and kinetics. The choice of the main (pre-activated) gas and the direction of gas flow largely affect the conversion and energy cost, while the gas inlet position during separate addition only influences the product distribution.