Enhancing hydrogen production from methane steam reforming using a palladium-based membrane reactor inserted with triple-helix structure

Membrane reactor (MR) represents an ideal technology for simultaneously producing and purifying hydrogen, holding significant potential in future clean energy systems. This study developed a new triple-helix insert enhanced membrane reactor (I-MR) for hydrogen production via methane steam reforming. By combining experiments with theoretical limit calculations, the performance of conventional reactor (CR), original MR (O-MR), and I-MR was systematically compared. Results demonstrate that MRs achieve forward reaction shift through hydrogen separation, enabling methane conversion exceeding those of CR and even thermodynamic equilibrium states. Compared to CR, I-MR achieves 27.1–75.8 % higher conversion within the 400–500 °C range, with more pronounced improvements at higher temperatures. Furthermore, the triple-helix insert effectively suppressed concentration polarization by promoting hydrogen mixing and redistribution, significantly boosting reaction efficiency. At 450 °C, the I-MR achieved an average 19.5 % higher methane conversion than the O-MR and demonstrated superior low-temperature activity across a broader temperature range. Moreover, under the CR reaction benchmark at 700 °C, I-MR maintained equivalent conversion capability while reducing the required temperature by ∼199.1 °C. Compared to O-MR, I-MR achieved a maximum temperature reduction of ∼52.6 °C, demonstrating potential for efficient hydrogen production under mild conditions. Also, the I-MR achieved stable operation for 25 h without noticeable carbon buildup or deactivation. The above results demonstrate the reliable role of the new triple-helix insert structure in enhancing hydrogen production within membrane reactors, indicating the potential of low-energy hydrogen production technologies.