Solar propane steam reforming offers a promising solution for hydrogen production, effectively addressing the challenges associated with hydrogen transportation and facilitating solar energy storage. In this context, the present study employs a combination of computational fluid dynamics and response surface methodology to optimize a multi-layer porous propane steam reformer. The research specifically emphasizes the influence of non-uniform catalytic porous structures on hydrogen production efficiency. The developed multi-objective optimization aims to identify the optimal combination of pore sizes to enhance propane conversion and hydrogen production rate while minimizing pressure drop. The optimized configuration achieved an 11.22% reduction in pressure drop, as well as 6.83% in hydrogen production and 8.04% in propane conversion, compared to the optimized uniform configuration of the solar porous reformer presented in our previous study (Jahangir et al., 2022) [1]. Furthermore, it was found that utilizing a multi-layer porous structure results in a more uniform temperature gradient, allowing a greater portion of the reformer to engage in the catalytic reaction. This is beneficial for reducing the potential risks of catalyst sintering and coke formation.

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