An experimental and modeling study aiming to enhance the performance of OSR of a methane fuel processor via Box-Behnken design

OSR is the energy efficient hydrogen production route used in small scale fuel processors. The performance of the methane OSR catalyst is crucial for the overall performance of FPs. Current work proves the activity and hydrogen selectivity of OSR catalyst can exceed thermodynamic limits if the contact time is defined properly. It furtherly shows the intricate nature of OSR, comprising synchronous series and parallel reactions, can be modeled parsimoniously unveiling the effect of parameters. Results of total 27 experiments according to a Box-Behnken (BB) design revealed higher CH4 conversion values were experimentally obtained for higher temperature, higher S/C feed ratio and lower C/O2 feed ratio with certain exception(s) for S/C feed ratio; however, mostly lower CH4 conversion values were observed for higher catalyst weight, i.e. higher contact time. Contrary to the conventional practice of including up to quadratic terms in the BB models, statistical analysis shows the necessity of including 3rd order two-way interaction terms in the models. The most statically significant 3rd order interaction terms were those between W and S/C, which are required to explain the unexpected partial effects of W and S/C on response variables. [Display omitted] •Bimetallic Pt-Ni/γ-Al2O3 as an effective catalyst for Oxidative Steam Reforming (OSR).•Use of Box-Behnken (BB) design to understand effect of reaction conditions on H2 selectivity and CH4 conversion.•Parsimonious models proposed for CH4 conversion, H2 concentration and H2/CO ratio.•Explanation of selectivity and conversion values exceeding thermodynamic limits in synchronous series&parallel reactions.•Necessity for addition of statistically significant 3rd order interaction terms to BB models.