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Design and Production of Hydrogen Gas by Steam Methane Reforming Process -

A Theoretical Approach

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 IJSTE - International Journal of Science Technology & Engineering | Volume 3 | Issue 01 | July 2016
ISSN (online): 2349-784X

Design and Production of Hydrogen Gas by Steam

Methane Reforming Process - A Theoretical
Approach
Safaa Salim Said Al Khusaibi
Department of Mechanical and Industrial
Caledonian College of Engineering, Sultanate of Oman
Dr. Lakkimsetty Nageswara Rao
Department of Mechanical and Industrial
Caledonian College of Engineering, Sultanate of Oman

Abstract
Hydrogen is considered in many counties to be an important alternative energy vector and a bridge to a sustainable energy future.
Hydrogen is not an energy source. It is not primary energy existing freely in nature. Hydrogen is a secondary form of energy that
has to be manufactured like electricity. Hydrogen can be produced from a wide variety of primary energy sources and different
production technologies. Currently, much research has been focused on sustainable and environmental friendly energy. Steam
methane reforming (SMR) is widely used in industry to make hydrogen. There is also interest in the development of much
smaller technology to produce hydrogen as a feed-stock for fuel cells. In this project report, the Steam reforming is studied and
done many research about the various production methods of hydrogen. In addition to this information, literature review about
SMR process and other processes of hydrogen production was highlighted. Also, the process description of steam methane
reforming (SMR) with flow sheet was discussed. Material and energy balance is calculated to insure the quality of this plant and
project. Furthermore, designing two equipment’s which are CO2 absorber and Shift reactor and studying the cost estimation of
this plant.
Keywords: Hydrogen Production, Steam Methane Reforming, Material and Energy Balance, Equipment
________________________________________________________________________________________________________

I. INTRODUCTION

Nowadays there is a wide world movement to explore the practical, reliable, and economic use of renewable energy. For these
and other reasons, alternative fuels are increasingly being pursued all over the world. There have been many proposals brought
forward to produce sustainable alternative fuels, such as biomass, solar, wind, bio-oils, ethanol and hydrogen. Among these,
hydrogen is considered to be a key fuel in the future. There are many projects and report study about Hydrogen production plant,
but using different technologies in order to achieve and to design a feasible and environmental chemical plant with different
capacities. Balat and Kirtay investigated the production of hydrogen using Biomass, (Balat &Kirtay, 2010). Molburg and Doctor
have showed that employing CO2-capture technologies combined with Texaco and Shell integrated gasification combined-cycle
(IGCC) power systems that produce both merchant hydrogen and electricity, (Molburg & Doctor, 2003). In 2001, Czernik et al.,
examined the Biomass as a product of photosynthesis is a renewable resource that can be used for sustainable production of
hydrogen, (Czernik et al, 2001)

II. METHODOLOGY

General Description of Process

The off-gas refinery off-gas is mixed with suitable quantities of recycle H2 and steam. At presence of Nickel based catalyst (Ni)
steam react with Methane to yield Carbon Monoxide and Hydrogen.
H2O + CH4 CO + H2…............ (1)
Additional hydrogen can be recovered by lower temperature gas-shift reaction with Carbon Monoxide produced.
CO + H2O CO2 + H2 ………... (2)
The shift reaction occurring in the HT shift converter produces additional H2.The hot syngas leaving the shift converter is
used to preheat boiler feet water. The H2 rich steam then enters a pressure swing adsorber (PSA), which separate H2 from off-
gases. The PSA off-gas is used to supplement external fuel for combustion in the reformer furnace.

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 Design and Production of Hydrogen Gas by Steam Methane Reforming Process - A Theoretical Approach
(IJSTE/ Volume 3 / Issue 01 / 084)

Fig. 1: SMR process- Basic flow sheet, (Jaiswal & Roy, 2013).
The carbon dioxide and any remaining carbon monoxide are then removed by passing the gases through a zeolite sieve. From
time to time, the vessel containing the sieve is taken out of the gas stream and flushed with hydrogen to displace carbon dioxide
and regenerate the sieve. To obtain a sustainable (i.e. zero emission of greenhouse gases) production of hydrogen, the carbon
dioxide is captured and stored or used.

III. MATERIAL BALANCE OF HYDROGEN GAS

The material balance for hydrogen gas production was shown in the table 1
Table – 1
Material balance of H2 Production
Stream Component Mole% Kgmole/hr
CH4 94.5 4243.1
C2H6 3.25 145.93
C3H8 0.2 8.98
Reformer
C4H10 0.05 2.25
CO2 0.7 31.43
N2 1.3 58.37
N2 0.23 58.37
CO 14.46 3722.251
Shift CO2 0.12 31.43
Reactor CH4 3.30 848.62
H2O 39.18 10084.662
H2 42.72 10996.132
N2 0.23 58.37
CO 5.06 1302.788
CO2 CO2 9.52 2450.89
Absorber CH4 3.30 848.62
H2O 29.78 7665.199
H2 52.12 13415.596
N2 0.25 58.37
CO 5.59 1302.788
CO2 0.11 24.509
PSA
CH4 3.64 848.619
H2O 32.88 7665.199
H2 57.54 13415.596
H2 99.98 13348.518
Product
CO2 0.0002 0.025

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 Design and Production of Hydrogen Gas by Steam Methane Reforming Process - A Theoretical Approach
(IJSTE/ Volume 3 / Issue 01 / 084)

IV. ENERGY BALANCE OF HYDROGEN GAS

The energy balance for hydrogen gas production was shown in the table 2
Table – 2
Energy balance of H2 Production
Equipment Heat flow rate (𝑄), 𝑘𝐽/ℎ𝑟
Inlet 139.34 × 106
Reformer
Outlet 751.469 × 106
Inlet 275.86 × 106
Shift Reactor
Outlet 358.406 × 106
Inlet 56.912 × 106
CO2 Absorber
Outlet 132.43 × 106
Inlet 9.25 × 106
PSA
Outlet 78.43 × 106

V. PROCESS EQUIPMENT DESIGN CALCULATIONS

CO2 Absorption Column Design

Assumption: made in this type of absorber is that only CO2 is absorbed and all other gases act as a inert in MDEA solution
Basis: 99% of CO2 is absorbed
Total gas flow rate of stream containing CO2,(G1 ) = 25741.47kmole/hr
Mole fraction of CO2 in Inlet gases,(𝑦1 ) = 0.095 mole
𝑦
Mole ratio of CO2 stream in Inlet gases, (Y1 ) = 1⁄(1 − 𝑦 ) =0.105 mole……….. (3)
1
Gas flow rate of inert gases,(G𝑠 ) = G1 × (1 − 𝑦1 ) = 23290.57 kmole/hr …… ... (4)
CO2 gas entering= 2450.89 kmol/hr,Therefore, CO2 absorbed= 2426.38 kmol/hr
CO2 leaving= CO2 entering − CO2 absorbed = 24.50 kmol/hr ……………. … (5)
Mole fraction of CO2 in outlet gases, (𝑦2 ) = 0.0011 mole
𝑦
Mole ratio of CO2 stream in outlet gases, 𝑌2 = 2⁄(1 − 𝑦 )=0.00110………….... (6)
2
Equation of equilibrium line, Y = 1.2X …………………………….…………… (7)
Y
Mole ratio of liquid in inlet,(X1 ) = 1⁄1.2 = 0.09
Assuming a pure MDEA solution is used for absorption, Therefore x2 = 0
Now, Material balance equation is,
𝐺𝑆 (𝑌1 − 𝑌2 ) = 𝐿𝑆 (𝑋1 − 𝑋2 )………………………………………………………... (8)
kmol kmol
LS = 27669.2 ,Pure solvent (water) rate,(LS ) = 27669.2
hr hr
L
Liquid flow rate at the top of the tower,(L2 ) = S⁄(1 − x )=27669.2 kmol/hr….(9)
2
Liquid flow rate at the bottom of the tower, (L1 )= LS+CO2 absorbed
=30095.58 kmol/hr………………. (10)
G S
Gas flow rate of CO2 absorbed at the top of tower, (G2 ) = ⁄(1 − 𝑦 )
2
=23315.08 kmol/hr …... (11)
Now, Mass balance equation:G1 y1 + L2 x2 = G2 y2 + L1 x1 ………………….…. (12)
x1 = 0.081 mole
Calculation of column diameter
Average Gas density= 2.86 kg/m3
Liquid density= 1038 kg/m3
According to (table 11.3) on page 776, let us choose Pall ring metal as packing material,
Flow parameter,
0.5
(FLV ) = (L1⁄G ) × (𝜌𝐺⁄𝜌𝐿 ) =0.061 ……………………………….... (13)
1
From graph between FLV and pressure drop (ΔP = 1.5 in. H2O/ft), 𝐶𝑠 𝐹𝑝 0.5 ⱴ 0.05 = 1.7
Where,CS = Fluid Capacity factor,Fp = Packing factor , ,ⱴ = Kinematic Viscosity, m2 /sec
Average viscosity ( 𝜇) = 7.28 × 10−5 kg/m. s
𝜇
Kinematic viscosity (ⱴ) = ( ⁄𝜌𝐺 ) == 0.0917m2 /hr = 25.472 cSt…………… (14)
Fluid capacity factor (CS ) = 2.02⁄ 0.5 0.05 =0.321………………………........ (15)
𝐹𝑝 ⱴ

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 Design and Production of Hydrogen Gas by Steam Methane Reforming Process - A Theoretical Approach
(IJSTE/ Volume 3 / Issue 01 / 084)

(𝜌𝐿 −𝜌𝐺 ) 0.5

Flood gas velocity(UNF ) = CS × ( ) =1.86 m/s………………………..... (16)
𝜌𝐺
Taking the operating velocity as 60% of the flooding velocity, Operating velocity
(US ) = 0.6 × UNF =1.12 m/s………………………………........... (17)
Volumetric flow rate of gas= 112895.476 m3 /hr== 31.36 m3 /𝑠𝑒𝑐
Assume 80% flooding, Tower cross sectional area(AT ) = Volumetric flow rate⁄0.8 U
S
= 35.12 m2 ………………………………………….……........ (18)
A × 4⁄
Tower diameter(DC ) = √ T π=6.69 m ……………………................ (19)
Calculation of column height, 𝑍 = 𝑁𝑂𝐺 × 𝐻𝑂𝐺 …………………………….……. (20)
Where, 𝑍 = Height of the tower, m
NOG = Number of overall gas phase transfer unit
HOG = Overall height of gas phase transfer unit, m
Number of overall gas phase transfer unit,
mG y1 mG
NOG = (1⁄ mG ) ln [(1 − ) + ]……………………. (21)
L y2 L
1−( )
L
G
Where, m = Slope of the equilibrium line, G/L = Slope of the operating line,m = 1.2, S⁄L = 0.83
S
NOG = 73.44 ≈ 73
Overall height of gas phase transfer unit, 𝐻𝑂𝐺 = G⁄𝐾 𝑎 …………………....….. (22)
𝐺
Where, G=Average gas flow rate per unit area, kmol/hr. m2
𝐾𝑦 𝑎 = Overall gas-phase mass transfer coefficient, kmol/hr. m2. mole fraction
𝑃 = partial pressure of CO2, atm
G
G1 = 1⁄A ……………………………………………….… (23)
T
2
= 733.06 Kmol/hr. m
G2 = 663.96 Kmol/hr. m2
(G − G2 )⁄
Average gas flow rate per unit area(G) = 1 2 =698.51 kmol/hr. m ….. (24)
2

Wetting rate, = L⁄𝜌 × 𝑎 =0.0081 m2/hr …………………………………….… (25)

𝐿
𝜌 × 𝐷 × US⁄
Reynolds Number, (𝑁𝑅𝑒 ) = 𝐺 μ =293000 ………………………..… (26)
𝐻𝑂𝐺 = 1.14m
 The column height(𝑍) = 𝑁𝑂𝐺 × 𝐻𝑂𝐺 = 83.22 m
The design specifications of CO2 Absorber Column was shown in table 3.
Table – 3
Specification of CO2 Absorber Column
Parameter Description
Tower MOC SS316
Tower Diameter 6.69 m
Height of Tower 83.22 m
Tower support Skirt support
Skirt MOD SS316
Skirt Height 4m
Type of Packing Pall ring
Packing MOD metal (SS)
Packing support Stacked packing

VI. CONCLUSION

Hydrogen is seen by many as key solutions for the 21st century, enabling clean efficient production of power and heat from a
range of primary energy sources. Energy is the very lifeblood of today’s society and economy. Our work, leisure, and our
economic, social and physical welfare all depend on the sufficient, uninterrupted supply of energy. As per the literature, the
steam reforming process appears as the most feasible and economical technology to produce hydrogen with high quality.
Material and energy balances were calculated for all process equipment’s of SMR process. Also, designing of the process plant
equipment is very essential for the process flow diagram.

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 Design and Production of Hydrogen Gas by Steam Methane Reforming Process - A Theoretical Approach
(IJSTE/ Volume 3 / Issue 01 / 084)

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