Detailed engineering of small-scale reactors for decentralized hydrogen production

Hydrogen is increasingly recognized as a key energy vector in the global transition towards clean and sustainable energy systems. At present, the majority of hydrogen is produced through steam methane reforming (SMR), a mature and widely adopted process that, however, is responsible for significant CO₂ emissions. Electrified steam reforming, when integrated with the water-gas shift (WGS) reaction and powered by renewable electricity, represents a promising pathway to decarbonize hydrogen production. The use of decentralized, small-scale reactor systems further enhances this approach by enabling on-site hydrogen generation, thus minimizing transportation-related challenges and costs. This thesis presents the detailed engineering design of a compact reactor system for decentralized hydrogen production. The work focuses on the chemical and thermal design of an intensified unit that combines an electrified steam reformer, a water quench section, and a WGS reactor within a single vessel. The design is based on material and energy balances provided by SYPOX, a Munich-based startup developing innovative reactor technologies for the direct electrification of thermochemical processes. The subsequent phases of the study include material selection and the preliminary mechanical design of the reactor, with particular attention to compliance with pressure vessel codes, structural integrity, and the management of thermal stresses. The objective is to provide a comprehensive design framework for efficient, scalable, and sustainable small-scale hydrogen production systems, bridging the gap between conceptual innovation and engineering feasibility. Ultimately, this work contributes to the advancement and deployment of decentralized hydrogen technologies, which are crucial to achieving global decarbonization goals.