The spread of renewable sources has boosted the emerging Power-to-Methane (PtM) concept as an attractive strategy for turning surplus power into Synthetic Natural Gas (SNG). PtM is founded on CO₂ methanation, a highly exothermic process that renders appropriate heat management challenging in conventional reactors. Hence Process Intensification (PI) may provide a breakthrough. This contribution presents a Computational Fluid Dynamics (CFD)-aided conceptual design of a heat-exchanger wall-coated methanation reactor. The design is based on a reactor formed by single-pass stacked plates comprising a reacting network of multiple channels coated with NiAl(O)_x. The reactor is evaluated at industrially relevant operating conditions with an undiluted stoichiometric feed. A 3-D reaction channel is parametrised to define a design point that guarantees a minimum CO₂ conversion of 95%, maximising throughput without hot spot formation. The plate manifold is 2-D dimensioned to keep an even flow distribution as a function of the number of channels. The entire stacked plate is 3-D simulated to corroborate the findings of former design stages and discuss the effect of the length of the channels on reactor performance. The proposed conceptual design sets a feasible PI base case to overcome the shortcomings of conventional reactors for PtM applications.

可再生能源的普及推动了新兴的电能转甲烷 (PtM) 概念，将其作为将剩余电力转化为合成天然气 (SNG) 的一种有吸引力的策略。PtM 建立在 CO ₂甲烷化的基础上，这是一种高度放热的过程，使常规反应器中的适当热管理具有挑战性。因此，过程强化 (PI) 可能会提供一个突破。此贡献介绍了换热器壁涂层甲烷化反应器的计算流体动力学 (CFD) 辅助概念设计。该设计基于由单程堆叠板形成的反应器，该反应器包括多通道反应网络，并涂有 NiAl(O) _x. 反应器在工业相关操作条件下使用未稀释的化学计量进料进行评估。对 3-D 反应通道进行参数化以定义一个设计点，该点保证最低95% 的CO ₂转化率，在不形成热点的情况下最大化吞吐量。板式歧管采用二维尺寸设计，以保持作为通道数量函数的均匀流量分布。对整个堆叠板进行 3-D 模拟，以证实先前设计阶段的发现，并讨论通道长度对反应器性能的影响。所提出的概念设计设定了一个可行的 PI 基础案例，以克服用于 PtM 应用的传统反应器的缺点。