Process simulation and optimisation of hydrogen production from natural gas via steam methane reforming: Aspen hysys simulation investigation

Michael  Ogbuatu; Kenechukwu  Enenebeaku; Chritogonus  Akalezi; Stanley Toochukwu Ekwueme; Ali  Billar; Ijeoma  Duru; TochukwuIfeanyi  Nwakile

doi:10.62638/ZasMat1296

Authors

Michael Ogonnaya Ogbuatu Department of Chemistry, Federal University of Technology, Owerri, Nigeria Author
Kenechukwu Conrad Enenebeaku Department of Chemistry, Federal University of Technology, Owerri, Nigeria Author https://orcid.org/0000-0003-1659-6550
Chritogonus Oudney Akalezi Department of Chemistry, Federal University of Technology, Owerri, Nigeria Author
Stanley Toochukwu Ekwueme Department of Petroleum Engineering, Federal University of Technology, Owerri, Nigeria Author https://orcid.org/0000-0003-3446-0905
Alex Bilar Ali Department of Chemistry, Federal University of Technology, Owerri, Nigeria Author https://orcid.org/0000-0002-4764-1177
Ijeoma Akunna Duru Department of Chemistry, Federal University of Technology, Owerri, Nigeria Author https://orcid.org/0000-0002-1427-0816
TochukwuIfeanyi Nwakile Department of Chemistry, Federal University of Technology, Owerri, Nigeria Author https://orcid.org/0009-0006-0362-0944

DOI:

https://doi.org/10.62638/ZasMat1296

Abstract

The growing demand for hydrogen in the energy sector necessitates enhanced methods for its production. Presently, natural gas remains the primary feedstock for commercial hydrogen production. While green hydrogen production from renewable sources is gaining attention, it still faces economic challenges compared to fossil-derived hydrogen. This study focused on simulating hydrogen production from natural gas using the steam methane reforming (SMR) process. The simulation employed Abbas et al (2017) kinetics over 18 wt. % NiO/a-Al₂O₃catalyst within Aspen HYSYS V11 software and utilized the Peng Robinson fluid property package. Sensitivity analyses were conducted, emphasizing parameters such as temperature, pressure, molar flow rate of steam, and reactor volume. The goal was to optimize various process outcomes, including methane conversion, hydrogen selectivity and yield, methane selectivity, CO selectivity and yield, CO₂ selectivity and yield, H₂/CO ratio, and hydrogen production. The results indicated that methane conversion and selectivities for hydrogen, carbon monoxide, and carbon dioxide increased with rising temperatures and decreased with higher pressures. Conversely, CO conversion and methane selectivity decreased with increased temperature but rose with higher pressure. These outcomes aligned with Le Chatelier's principle for both endothermic and exothermic reactions. The analysis of steam molar flow revealed increased methane conversion due to the higher reaction temperature provided by steam and a higher steam-to-carbon ratio. The simulation demonstrated the economic viability of hydrogen production through the steam methane reforming process. Additionally, it highlighted the significant contribution of steam sales to the overall economic feasibility of the process. Overall, the study underscores the technical feasibility of hydrogen production from natural gas using the steam methane reforming process.

Keywords:

Steam methane reforming, Response surface methodology, CH4 conversion, Hydrogen selectivity, Process simulation

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