Towards sustainable hydrogen production: Integrating electrified and convective steam reformer with carbon capture and storage

This work reports the design of a process for hydrogen production based on electrified steam methane reforming (e-SMR) coupled with a convective reforming (convective SMR) and carbon capture and storage (CCS) as an alternative to conventional fuel-fired reforming to reduce natural gas (NG) consumption as well as carbon dioxide emissions. The energy required by the reforming reaction is supplied by direct electric heating instead of burning fossil fuel in the radiant section of a furnace, saving 35 % NG and reducing CO2 emission by 29 %. Implementing convective SMR reduces the electric load of the main e-SMR reactor and ensures a slightly higher thermal efficiency (80.2 %) compared to conventional fuel-fired reforming (78.9 %). Further CO2 emissions (85 %) and NG consumption reduction (50 %) are possible by adopting amine-based CO2 capture. If coupled with an energy integration scheme, it is possible to capture 75 % of the CO2 produced, preserving high energy efficiency (79.4 %). This requires only a 14 % increase in capital costs, which is strongly beneficial compared to applying CO2 capture to flue gases of the fuel-fired reforming (69.8 % efficiency and 80 % more capital costs). The process based on e-SMR coupled with convective SMR and CO2 capture ensures a levelized cost of hydrogen (LCOH) of 0.281 € Nm−3 H2, which is much lower than the conventional fuel-fired reforming with CO2 capture applied to flue gases (0.309 € Nm−3 H2). Moreover, it has comparable CO2 emissions (1.59 vs 0.99 kg CO2 emitted kg−1 H2) but produces lower CO2 (6.39 vs 9.88 CO2 produced kg−1 H2) compared to fuel-fired reforming due to using renewable electricity as energy source for the SMR. Compared to conventional fuel-fired reforming, the same process provides similar LCOH (0.283 vs 0.282 € Nm−3 H2) but with drastically lower CO2 emissions (1.59 vs 8.99 kg CO2 emitted kg−1 H2).