Enhanced hydrogen production in steam methane reforming: Comparative analysis of industrial catalysts and process optimization

Abstract

Methane is often produced using fossil fuels or renewable energy sources and utilized as a feedstock for generating syngas. Syngas which is a mixture of hydrogen (H2) and carbon monoxide (CO) could be produced through a conventional process, steam methane reforming (SMR). The goal of this research was to examine the activity of three industrial catalysts (Type 1, Type 2, and Type 3) Ni-based supported on alumina in the SMR process. The operating parameters of the SMR process were analyzed using the response surface method (RSM) with a central-composition design (CCD). For analysis and optimization of H2 production and CH4 conversion via RSM, independent variables such as temperature reaction (550–700 °C), gas hourly space velocity (GHSV) (126–185 Scc/gcat.min), and steam/carbon (S/C) molar ratio (1.5–2.1) were used. In addition, various methods were used to analysis the structural characteristics of catalysts both before and after the reaction. Several optimum options were proposed by the design expert software; among industrial catalysts, Type 3 showed the greatest CH4 conversion (72.59 %), H2 yield (78.60 %), and lowest coke formation (7.94 wt%) due to its high surface area and more evenly distributed active sites.