Challenge
High-Temperature catalytic systems depend on precise thermal management to maintain reaction stability, process efficiency, and long-term operational reliability.
GTI Energy faced this challenge while developing a pilot-scale Novel Electric Reformer designed to convert renewable natural gas, recycled CO2, hydrogen, and steam into synthesis gas for downstream production of sustainable aviation fuel and other renewable fuels. Unlike conventional fired reformers, the compact electrically heated reactor concentrated heat generation and catalytic conversion within a significantly smaller process envelope.
This architecture required more than simply generating sufficient heat. It required delivering the right amount of heat, in the right locations, throughout the reactor while maintaining stable operating conditions during continuous high-temperature operation.
Thermal instability within the reactor could directly affect catalyst performance, synthesis gas conversion efficiency, reactor temperature control, carbon formation, and overall system reliability. Computational modeling also showed that uniform heat input was not the optimal solution. The reactor required higher heat flux upstream and progressively lower heat input downstream to maintain the desired thermal profile while minimizing localized hot spots and excessive catalyst temperatures.
To successfully validate the pilot-scale system, GTI Energy required a thermal architecture capable of delivering staged heat distribution, maintaining controlled heat transfer under continuous operating load, and supporting reliable operation throughout extended runtime testing.
Solution
GTI Energy integrated custom-engineered Watt-Flex® thermal architecture from Dalton into the E-Reformer reactor design to support controlled heat delivery across the catalyst bed.
Rather than applying uniform heat throughout the reactor, the system required staged heat distribution. GTI Energy's modeling showed that the reforming process benefited from higher heat input at the front of the reactor and progressively lower heat input downstream. This approach helped maintain the required thermal profile while reducing the localized overheating risk and supporting catalyst stability.
Dalton engineered Watt-Flex® heaters with distributed wattage across three heating zones. Each 60-inch heater included a 48-inch heated section divided into 24-inch and two 12-inch segments, delivering different watt densities along the reactor length. In total, 36 Watt-Flex® heating elements were integrated directly into the E-Reformer architecture, with each heater producing 4.45 kW of power.
The Watt-Flex® split-sheath design also supported the mechanical requirements of the application. As operating temperature increased, the heater expanded to maintain tight contact with the surrounding protection sheath, improving conductive heat transfer under load. When cooled, the heater contracted to support removal and serviceability without damaging the surrounding assembly. Embedded thermocouples provided temperature monitoring during operation, while high-temperature lead construction supported the demanding reactor environment.
The result was not simply a heating component. It was an engineered thermal system designed around the reactor's operating profile, heat flux requirements, maintainability needs, and long-duration validation goals.
Results
The pilot-scale E-Reformer successfully demonstrated that engineered thermal architecture could support stable operation under demanding process conditions.
Across two validation campaigns, the system accumulated more than 555 hours of operating time, including a 301-hour renewable natural gas campaign and a 245-hour CO2/H2 campaign. During testing, the reactor maintained stable temperature profiles, achieved hydrocarbon conversion rates approaching 99%, sustained catalyst performance, and closely matched GTI Energy's computational modeling.
Perhaps most importantly, the thermal system performed as intended throughout validation. In describing the pilot-scale reactor, GTI Energy reported:
"Using this design and Dalton heaters, not technical problems, such as heater burnouts, arose during testing."
At the conclusion of the project, GTI Energy confirmed that the pilot-scale E-Reformer had successfully met its primary validation objectives and was ready to advance toward commercial-scale development. The project demonstrates how engineered thermal architecture can enable process stability, operational reliability, and technology validation in next-generation electrified process systems.
At a Glance
Application
GTI Energy developed a pilot-scale Novel Electric Reformer to convert renewable natural gas, recycled CO2, hydrogen, and steam into synthesis gas for sustainable fuel production. The electrically heated reactor required precise thermal management to support continuous catalytic operation.
Challenge
The reactor required staged heat delivery and controlled thermal distribution to maintain catalyst stability, optimize conversion efficiency, prevent localized overheating, and sustain reliable operation under continuous high-temperature conditions.
Solution
Dalton engineered a custom Watt-Flex® thermal system featuring distributed wattage, three-zone heat distribution, split-sheath, and integrated temperature monitoring to deliver the thermal profile required by the reactor.
Results
The pilot-scale system accumulated more than 555 hours of successful operation, achieved stable thermal performance and hydrocarbon conversion approaching 99% and advanced to commercial-scale readiness with no heater burnouts reported during validation testing.
Project Highlights
- 555+ Hours of validated operation
- 36 Custom Watt-Flex® heaters
- 3-Zone Distributed wattage architecture
- 99% Hydrocarbon conversion achieved
- 0 Heater burnouts during validation
- 1,100 kg/day Pilot-scale E-Reformer
