Factorial design of experiment (DOE) for parametric exergetic investigation of a steam methane reforming process for hydrogen production

Hydrogen is expected to play a significant role in future energy systems. The efficient production of hydrogen at a minimum cost and in an environmentally acceptable manner is crucial for the development of a hydrogen-including economy. The exergy analysis is a powerful tool to quantify sustainable development potential. An important aspect of sustainable development is minimizing irreversibility. The purpose of this study is to perform the exergy analysis of a steam methane reforming (SMR) process for hydrogen production. As a first step, an exergy analysis of an existing process is shown to be an efficient tool to critically examine the process energy use and to test for possible savings in primary energy consumption. The results of this investigation prove that the exergetic efficiency of the SMR process is 65.47%, and the majority of destroyed exergy is localized in the reformer with a 65.81% contribution to the whole process destroyed exergy. Next, an exergetic parametric study of the SMR has been carried out with a factorial design of experiment (DOE) method. The influence of the reformer operating temperature and pressure and of the steam to carbon ratio (S/C) on the process exergetic efficiency has been studied. A second-order polynomial mathematical model has been obtained through correlating the exergetic efficiencies with the reformer operating parameters. The results of this study show that the rational choice of these parameters can improve the process exergetic performance.