Manufacturing 28 MSCF/day of Hydrogen by Steam

Reforming
Mudassir Sarosh, Faisal Nazir, M. Khizar Aziz, Kamran Saeed & M. Kaiser
Faheem
NFC Institute of Engineering & Fertilizer Research, Faisalabad

Abstract
This report deals with the design calculations of Hydrogen by Steam Reforming along with their relevant aspects such
as material and energy Balances, Mechanical Designs, Instrumentation and Process Control, Hazop study and Cost
Estimation.

Five hydrocracking processes were in use in

Introduction

the U.S. with the estimated hydrogen of 63

Hydrogen has been an important gaseous raw

billion second largest use of hydrogen is in

material for the chemical and petroleum

petroleum

industries as shown in following table. World

Raw
material Product

hydrocracking processes are in use in the

hydrogenated
Phenol

Cyclohexnanol

billion ft3 / year. More than 12 hydrogen

Nitrogen

Ammonia

treating processes (hydrodesulphurization

Naphthalene

Tertralin

etc.) are being used the U.S., with hydrogen

Olien

Stearin

requirement 300 billion ft3 per year. Also

Carbon monoxide Methanol

hydrogen production in 1965 was estimated
2.7 trillion ft3 (7.170 million short tons). The
largest single production and use of hydrogen
is in the manufacture of ammonia. In
Pakistan many industries produces hydrogen
for this purpose. The second largest use of
hydrogen is in petroleum - refining process.

refining

process.

Five

U.S. with the estimated hydrogen of 63

methanol production requires large amount

of hydrogen. Large amount of hydrogen is
used in catalytic hydrogenation of vegetable
oils to produce solid fats.

Methodology
Main Methods of production of Hydrogen
1. Reforming of hydrocarbons

2. Partial oxidation of hydrocarbons

So we use natural gas for reforming process

3. Decomposition of hydrocarbons

because in Pakistan natural gas is in large

4. Coal gasification

abundance and as much cheaper.

5. Biological processes

Material and Energy Balances were applied

6. Thermochemical cycles

across following units:

7. Photochemical processes
8. Electrolysis
9. Coke, steam and air reaction
Our process is production of hydrogen from
hydrocarbon reforming. We can use steam
reforming of natural gas, steam reforming of
naphtha or partial oxidation of oil or natural

1.
2.
3.
4.
5.
6.

Desulfurizer
Reformer
HTS
LTS
Methanator
Compressor

Equipment was also designed for all the

above mentioned steps.

gas.
But in Pakistan gas is in large abundance and

Conclusion

much cheaper rates as compare to the

An economical design can be produced

naphtha. Naphtha operation requires 18%

that can yield a high value product for

more capital investment that of natural gas.

different applications. Industry imports

Furthermore, naphtha is expensive to be used

simple products that can synthesized by

as raw material, since it is distillation cut

high investments.

between gasoline and kerosene. The amount

of naphtha varies with market conditions.

References
1. PETER and TIMMERHAUS , Plant

The partial oxidation process requires more

Design and Economics for Chemical

capital investment then the steam reforming

Engineers, 2003.

plant because of an air separation plant, larger

2. PERRY , Chemical Engineers Hand

Book, 1997.

shift conversion, CO2 removal and gas clean

up is needed. Its principal disadvantage is the
necessity for providing 95-99% pure oxygen
ordinary obtained from air separation plant,
which adds both the plant investment and
operating cost.

3.

JHONSASSO, Plastics for Industrial

Uses, 1951.