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Methanol steam reforming inside micro-reactors is considered as one of the effective approaches for on-board supplying hydrogen for fuel cells. Porous copper fiber sintered felts (PCFSFs) are a new kind of catalyst support for micro-reactors developed in recent years. However, there is a lack of approach to control their porosity configurations due to their random structure. A two-step optimization method was proposed to optimize the PCFSFs’ porosity configuration. Firstly, the topology structures of PCFSFs were optimized based on the best flow distributions obtained from macroscopic numerical analyses, and two kinds of PCFSFs with twelve porosity distributions were fabricated through the multi-step mold pressing and solid-phase sintering method. Secondly, the porosity distributions of the semi-optimized PCFSFs were optimized by investigating their reaction characteristics under different gas hourly space velocities (GHSVs) and reaction temperatures. The results indicated that PCFSFs with porosity distribution along the Left-Right direction (PCFSF-LRs) exhibited better reaction performance than PCFSFs with porosity distribution along the Upside-Underside direction (PCFSF-UUs). The methanol conversion and H2 flow rate for the PCFSF-LRs with porosity distribution of 0.7–0.9–0.8 and 0.8–0.9–0.7 kept on a high level (above 92% and 0.59 mol/h, respectively), regardless of the change of GHSVs and reaction temperatures in most cases. The H2 selectivity of the PCFSF-LR of 0.7–0.9–0.8 was the highest under large GHSVs and all tested reaction temperatures. The demonstrated effect of counteracting, even reversing the conventional influence of the GHSV and temperature on the performance of methanol steam reforming may be attributed to the more uniform flow distribution in the two PCFSF-LRs.

In this study, the cascading metal foams were used as catalyst supports for constructing a new type of cylindrical laminated methanol steam reforming microreactor for hydrogen production. The two-layer impregnation method was used to load the Cu/Zn/Al/Zr catalysts, and the ultrasonic vibration method was then employed to investigate the loading performance of metal foams with different types and thicknesses. Furthermore, the effect of the type of catalyst placement, pores per inch (PPI) and foam type on the performance of methanol steam reforming microreactor was studied by varying the gas hourly space velocity (GHSV) and reaction temperature. Compared with two other types of catalyst placement studied, the microreactor containing catalyst-loaded metal foams without clearance cascading (3 × 2) showed the highest hydrogen production performance. When the PPI of the metal foam was increased from 50 to 100, both the methanol conversion and the H2 flow rate gradually increased. Our results also showed that a microreactor with Cu foam as a catalyst support exhibits increased hydrogen production and higher stability than those of a microreactor with Ni foam.

To optimise methanol steam reforming performance of cylindrical microreactor for hydrogen production, an error backpropagation algorithm was used to build a mathematical model for reaction performance of different microreactors for hydrogen production. Additionally, a genetic algorithm (GA) was utilised to process the computational model to obtain the optimum reaction parameters. The reliability of optimum reaction parameters of cylindrical microreactor for hydrogen production was verified by experiments. Firstly, take platemicroreactor as an example, the porosity of porous copper fiber sintered sheet (PCFSS), reaction temperature of methanol steam reforming for hydrogen production, injection velocity of the methanol and water mixture, and catalyst loading of PCFSS were considered as input data, whereas methanol conversion was used as output data. The computational model for specific testing system was gained by utilising input and output data from specific testing system to train the mathematical model for different microreactors, combining with matrix laboratory (MATLAB) neural network toolbox and designed MATLAB program. The Emax of 5% for plate microreactor and Emax of 3.2% for cylindrical microreactor verified the good predictive ability and reliability of the computational model for plate and cylindrical microreactor, indicating the reliability and universal applicability of the mathematical model for different microreactors. Secondly, the effects and mechanisms of PPI, reaction temperature, injection velocity, and catalyst loading on methanol conversion were studied, relying on the computational model. Finally, the optimum reaction parameters were acquired using GA, MATLAB neural network toolbox and designed MATLAB program. The validity of the optimum reaction parameters of cylindrical microreactor for hydrogen production was confirmed by experiments. This study provides a feasible method for methanol steam reforming performance optimisation for hydrogen production.

As environmentally friendly and high-energy density rechargeable energy storage devices, lithium-ion batteries (LIBs) have thriving prospects in the field of energy. The current collector, which serves as an important component of LIBs, significantly influences the electrochemical performance of the battery. Numerous efforts have been spent on the design and fabrication of high-performance negative current collectors in the field of LIBs to achieve excellent battery performances. These high-performance current collectors are mostly structuralized to achieve special functions. Hence, different types of structuralized current collectors used for LIB anodes are comprehensively discussed and summarized in this paper. The structuralized current collectors used in LIB anodes are classified into planar-plate-based special-surface current collectors and the 3D framework-based porous current collectors. Both types of the structuralized current collectors are further divided into the single-component and multicomponent current collectors. More subsections are provided and focus on providing description of the developing strategies, fabrication methods, electrochemical behaviors, in-depth reasons for high performances, and advantages and challenges for real applications of the structuralized current collectors in detail. Subsequently, the challenges and future research directions of structuralized anode current collectors are reasonably clarified. Based on an objective summary of the high-performance negative current collectors, this review provides an enlightening guide for the future development of current collectors and LIBs. The fundamental conclusions can also be extended to other energy storage devices.

Management of the produced carbon dioxide (CO2) is important to improve the performance of a liquid-feed direct methanol fuel cell (DMFC). This work investigates the CO2 bubble behaviors and the two-phase flow characteristics, using a single sinusoidal corrugated channel as the anode flow field. The magnitude and gradient of the fluid velocity in this channel is higher than the traditional straight pattern, as proven by tracking CO2 bubbles. The use of high magnitude and gradient of velocity enhances CO2 emission and fuel delivery, as well as increases the pressure drop. The vortices in the disturbance structure of the corrugated channel help uniformly deliver the reactants and separate bubbles away from the channel wall. Using excessive values of amplitude A and angular frequency W in the corrugated channel causes serious bubble deformation and extra energy consumption. The effect of disturbance structure is negligible with small values of these two parameters. The cell with a corrugated channel shows a higher performance at different feed rates and concentrations of the methanol fuel. The optimal value of A and W are respectively 0.1and 5. The visualization tests demonstrate that the appearance of CO2 bubbles in the corrugated channel is consistent with the simulation results.