In the present investigation a realistic two‐phase model accounting for the change in the total number of moles accompanying the reaction is utilized to explore a novel reactor configuration suggested for the methane steam reforming process. The suggested design is basically a fluidized bed reactor equipped with a bundle of membrane tubes. These tubes remove the main product, hydrogen, from the reacting gas mixture and drive the reaction beyond its thermodynamic equilibrium. The proposed novel design is also equipped with sodium heat pipes which act as a thermal flux transformer to provide the large amount of heat needed by the endothermic reaction through a relatively small heat transfer surface, assuring better reactor compactness. Two options for fluid routing through the membrane tubes are proposed; each is suitable for a certain industrial application. The performance of this novel configuration is compared with that of an industrial fixed bed steam reformer and the comparison shows the potential advantages of the suggested configuration.

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Steam reforming of light hydrocarbons is a key step for producing hydrogen and syngas for important processes in the petroleum and petrochemical industries. Since the establishment of the SMR process in 1930, research and development have led to improved catalyst performance and improved reactor tube materials. Since about 1970, new reactor configurations have been considered. The authors critically review recent attempts to radically improve the SMR reactor performance, analyze the areas of improvement and the suitability of proposed configurations for different reforming applications.

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Fluidized-bed membrane reactors (FBMR) are examined from a scale-up and practical point of view. Mathematical modeling is utilized to explore potential configurations for commercial FBMR steam methane reforming (SMR) as well as to quantify the effects of key design parameters such as membrane capacity, distribution of membrane surface between the dense bed and dilute phase, permeate side pressure, and sweep gas flow. Key factors affecting the performance of a commercial FBMR are analyzed and qualitatively compared with corresponding factors in packed-bed membrane reactors. Issues which pose challenges to the commercial viability of this technology are identified. These include maintenance of bed mobility in the presence of gas withdrawal, providing sufficient membrane capacity, wear, and mechanical forces on vertical surfaces.