Electrified steam methane reforming of biogas for sustainable syngas manufacturing and next-generation of plant design: A pilot plant study

[Display omitted] •Successful scale-up of the electrified steam methane reforming technology to industrial representative size.•eSMR enables fast thermal start-up and turndown with high stability and control.•An expanded operating envelope is possible with eSMR compared to fired reformers.•≥99 % energy efficiency at industrial scale.•Simplified eSMR design enables practically zero-emission plants. Electrification of the traditional steam methane reforming (SMR) technology for syngas manufacturing has a significant CO2 reduction potential and make it more feasible to operate in combination with carbon capture/utilization, especially if renewable electricity is used. This pilot plant study demonstrates the first operational experience with industrial-scale electrified steam methane reforming (eSMR) technology using biogas as sustainable carbon feedstock. Across an operating envelope spanning from combinations of 5 to 20 barg and 750 °C to 1000 °C, the eSMR produces syngas as expected from thermodynamics. However, without the thermal restrictions inherent in the SMR design, the eSMR can achieve higher temperatures, enables fast transient operation, with high stability and control, thereby increasing the overall performance and design flexibility. Initial thermal responses of the eSMR were tested, demonstrating fast start-up from an idle state to operating conditions, within 2.6 h, including heating from 630 °C to 900 °C. Furthermore, dynamic temperature control was also demonstrated with heating rates up to 330 °C/h. Experimental energy efficiency of the pilot reactor was quantified between 72 % and 80 %, with the residual being heat loss to the surroundings due to the relatively small scale. With further scale-up to ≥1 MW reactor capacity, efficiencies of ≥99 % are predicted with a specific electrical energy consumption of 1.0 kWh/Nm3 H2. Overall, the efficiency and operational flexibility are improved due to the direct electrical heating of the catalytic system. Combined with biogas as feedstock, this paves the way for attractive and competitive plant designs for sustainable and renewable production of chemicals and fuels.