Empty fruit bunch, a significant by-product of the palm oil industry, represents a tremendous and hitherto neglected renewable energy resource for many countries in South East Asia and Sub-Saharan Africa. The design and simulation of a plant producing pure hydrogen through autothermal reforming (ATR) of palm empty fruit bunch (PEFB) was carried out based on successful laboratory experiments of the core process. The bio-oil feed to the ATR stage was represented in the experiments and in the simulation by a surrogate bio-oil mixture of 11 organic compounds shown to be main constituents of PEFB oil from previous work, and whose combined elemental composition and volatility was determined to be as close as possible to that of the real PEFB bio-oil. The experiments confirmed that H2 yields close to equilibrium predictions were achievable using an in-house synthetised Rh-Al2O3 catalyst in a packed bed reactor. Initial sensitivity analysis on the plant revealed that feed molar steam to carbon ratio should not exceed 3 for the optimal design of the ATR hydrogen production plant. An overall plant efficiency of 39.4% was obtained for the initial design, this value was improved to 67.5% by applying pinch analysis to enhance the integration of heat in the design. The proposed design renders CO2 savings of about 0.56 kg per kg of raw PEFB processed. The proposed design and accompanying experimental studies together make a strong case on the possibility of polygeneration of H2, heat, and power from an otherwise discarded agricultural waste.

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The autothermal reforming (ATR) of acetic acid (HAc) as a model bio-oil compound is examined via bench scale experiments and equilibrium modelling to produce hydrogen and syngas. This study compares the performance of nickel (Ni-Al, Ni-CaAl) vs. rhodium (Rh-Al) for particulate packed bed (PPB), and of Rh-Al in PPB vs. Rh with and without Ceria for honeycomb monolith (‘M’) catalysts (R-M and RC-M). All PPB and M catalysts used Al2O3 as main support or washcoat, and when not pre-reduced, exhibited good performance with more than 90% of the HAc converted to C1-gases. The maximum H2 yield (6.5 wt.% of feed HAc) was obtained with both the Rh-Al and Ni-CaAl catalysts used in PPB, compared to the equilibrium limit of 7.2 wt.%, although carbon deposition from Ni-CaAl at 13.9 mg gcat−1 h−1 was significantly larger than Rh-Al’s (5.5 mg gcat−1 h−1); close to maximum H2 yields of 6.2 and 6.3 wt.% were obtained for R-M and RC-M respectively. The overall better performance of the Ni-CaAl catalyst over that of the Ni-Al was attributed to the added CaO reducing the acidity of the Al2O3 support, which provided a superior resistance to persistent coke formation. Unlike Rh-Al, the R-M and RC-M exhibited low steam conversions to H2 and CH4, evidencing little activity in water gas shift and methanation. However, the monolith catalysts showed no significant loss of activity, unlike Ni-Al. Both catalytic PPB (small reactor volumes) and monolith structures (ease of flow, strength, and stability) offer different advantages, thus Rh and Ni catalysts with new supports and structures combining these advantages for their suitability to the scale of local biomass resources could help the future sustainable use of biomasses and their bio-oils as storage friendly and energy dense sources of green hydrogen.