Holistic sustainabiliy in hydrogen production processes via steam methane reformation (SMR): thermodynamic optimizati̇on and techno-economic analysi̇s of integrated systems

Enhancing the efficiency and economic viability of Steam Methane Reforming (SMR), the dominant technology for hydrogen production, is of critical importance for sustainability goals. This thesis presents a holistic approach to address both the thermodynamic and operational inefficiencies present in a real industrial SMR plant. In this context, a thermodynamic optimization has been performed using Cycle Tempo software, based on the plant's annual average data. Subsequently, a comprehensive techno-economic analysis was conducted for the integration of a 222.73 kW micro gas turbine (MGT) to valorize the plantspecific, unutilized surplus hydrogen stream of 0.002 kg/s. The results indicate that the proposed integrated system significantly improves the plant's performance. The overall system energy efficiency increased from 43% to 64%, while annual CO₂ emissions were reduced by 664.57 tons (11.8%). The techno-economic analysis reveals an attractive payback period of 4.96 years for the MGT investment. The fundamental driver behind this feasibility is the powerful synergistic effect arising from the combination of two distinct benefits: of the total annual financial benefit of approximately $250,550, 67% originates from new electricity sales revenue, while 33% is derived from savings resulting from the optimized natural gas consumption. This study proves that combining process optimization with the valorization of waste streams offers an economically attractive and replicable pathway to enhance the overall sustainability of industrial hydrogen production.