Techno-economic Analysis and Optimization of Intensified, Large-Scale Hydrogen Production with Membrane Reactors

Abstract

Steam methane reforming (SMR) currently supplies 76% of the world’s hydrogen (H2) demand, totaling ∼70 million tonnes per year. Developments in H2 production technologies are required to meet the rising demand for cleaner, less costly H2. Therefore, palladium membrane reactors (Pd-MR) have received significant attention for their ability to increase the efficiency of traditional SMR. This study performs novel economic analyses and constrained, nonlinear optimizations on an intensified SMR process with a Pd-MR. The optimization extends beyond the membrane’s operation to present process set points for both the conventional and intensified H2 processes. Despite increased compressor and membrane capital costs along with electric utility costs, the SMR-MR design offers reductions in the natural gas usage and annual costs. Economic comparisons between each plant show Pd membrane costs greater than $25 000/m2 are required to break even with the conventional design for membrane lifetimes of 1–3 years. Based on the optimized SMR-MR process, this study concludes with sensitivity analyses on the design, operational, and cost parameters for the intensified SMR-MR process. Overall, with further developments of Pd membranes for increased stability and lifetime, the proposed SMR-MR design is thus profitable and suitable for intensification of H2 production.

Mixed Matrix Membranes Based on MFI Zeolite Nanosheets with Tunable Thickness for CO2/CH4 and H2/CH4 Separation

“…On the other hand, hydrogen (H 2 ) is widely considered as a kind of efficient and clean fuel, which will play a pivotal role in the future energy system . The current H 2 mainly comes from NG steam reforming . Furthermore, adding H 2 into CH 4 transportation pipes (and separating them on the destination site) is an effective way for H 2 transportation .…”