Hydrogen provides a potential solution for replacing fossil fuels and alleviating their environmental impacts on a large scale. Hydrogen fuel cell vehicles are an ideal alternative to conventional fuel vehicles that account for the majority of petroleum consumption. However, several critical barriers to on-board hydrogen production systems for fuel cells remain, typically including high reaction temperatures, high energy consumption, and high carbon emissions. In this study, a novel method of autothermal reforming of methanol promoted by in-situ CO2 adsorption is proposed for low-temperature hydrogen production with enhanced efficiency and low carbon footprint. The feasibility of the method is verified by numerical simulation of a reactor filled by a well-mixed bed of reforming catalyst (CuO/ZnO/Al2O3) and CO2 adsorbent (hydrophobic modified activated carbon), which promotes hydrogen production with CO2 capture by forward-shifted equilibrium of the autothermal reforming reaction. A multiple-port air supply design is adopted to supply reaction heat and homogenize the temperature field along the shell of the reaction tube, so as to reduce heat transfer losses and achieve thermal self-sustainability. With a feed temperature of 200 °C and an operating pressure of 5 bar, hydrogen production with a yield up to 0.22 g/(gcatalyst·h) and purity up to 86.86% (inert gas impurity) can be achieved. Furthermore, three feeding and filling designs of the reactor are investigated for the optimization of reactor operation. Simulation results show that the maximum temperature difference inside the reaction chamber decreases significantly from 51.6 °C to 14.6 °C after adjustment of the air feeding design. After in-situ carbon dioxide adsorption optimization, the outlet hydrogen purity increases by 21.44% (relative), the hydrogen yield increases from 2.49 mol/molCH3OH to 2.73 mol/molCH3OH, and the carbon monoxide concentration decreases sharply from 2188.51 ppm to 526.51 ppm. The CO2 is completely captured during the hydrogen production process while a high CO2 concentration of 99.97% (due to the presence of residual gases) is achieved after the regeneration of CO2 adsorbent. The autothermal reforming reactor design proves successful in eliminating external heating by combustion and thus achieves increased methanol conversion and reduced carbon emissions at low temperatures. The optimized reactor can satisfy the hydrogen demand of fuel cells in portable and stationary applications after scaling up, and provides a potentially promising approach for on-site hydrogen production for fuel cells at low operating temperatures.
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