In this project, a ceramic microchannel reactor that is being developed to combine heat-exchanger and catalytic-reactor functions. Figure 1 is an exploded view that illustrates the internal geometry for two layers of microchannels, and a photograph of the microchannel reactor. The current reactors use four layers, with two using a catalyst washcoat and the other two being non-catalytic. The reactor body is 50 mm wide, 100 mm long and approximately 5 mm thick. The current reactors are fabricated by industrial collaborator CoorsTek, Inc. using 94% alumina.

Each layer is fabricated with a near-net-shape pressing process and layers are laminated in the unfired "green" state. After firing, a single hermetically sealed polycrystalline ceramic body is produced. Rhodium catalyst has been subsequently deposited within the reactor onto a thermally stable Sr-hexaaluminate support structure. This ceramic microchannel reactor is now being developed for steam reforming of methane for SOFC and other applications.