Thermodynamic analysis and step-by-step performance and emission optimization of a real steam methane reforming (SMR) hydrogen production plant

Hydrogen is an energy carrier with great potential for sustainable production processes. Steam Methane Reforming (SMR) is one of the most widely used techniques in the industry among hydrogen production methods, with its high efficiency and low cost. However, due to its environmental disadvantages such as being based on fossil fuels and carbon emissions, optimization studies to be carried out for this method are very valuable in terms of sustainability. In this study, thermodynamic performance analysis and optimization of a real hydrogen production plant were simulated using Cycle Tempo software. Using energy and exergy analysis; heat losses, exergy destruction and carbon emissions in the system were examined in detail. Then, optimization analyses were carried out. With optimization studies, energy efficiency increased by 14 %. Natural gas consumption was reduced by 20 %. CO 2 emissions were reduced by 15.15 %, thus reducing annual CO 2 emissions by 585.59 tons. In addition, the efficiency of the hydrogen production process was increased by reducing the steam-carbon (S/C) ratio from 3.74 to 3.02, and the risk of carbon accumulation in the reformer was minimized. As a result of the optimization, it was proven that SMR processes can be made more economical and environmentally friendly by improving thermal and exergy efficiency compared to the real system. In this context, the performed optimization provides a significant contribution for researchers and manufacturers to enhance energy efficiency, reduce operational costs and ensure environmental sustainability in hydrogen production processes. • Loss analysis of a real system was made in detail. • Probable weak sides of the plant in terms of performance and loss were evaluated. • Inefficiencies were minimized with the optimization studies. • A more environmentally friendly and economically optimized system was aimed at obtaining it. • Both environmental sustainability and operational costs were improved.