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

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.