Process Technology Quick Reference Cards

Hydrogen

Chapter from the Process Technology Quick Reference Cards.

HYDROGEN PRODUCTION (SMR / ATR)

Process Objective

Produce high-purity hydrogen from natural gas or refinery fuel gas via steam methane reforming or autothermal reforming.

Key Operating Variables

Variable	Typical Range	Effect / Notes
Reformer Outlet Temp	1,500-1,650°F	Higher T → more conversion, higher H2 yield
Steam/Carbon Ratio	2.5-5.0 mol/mol	Higher S/C → more H2, less coking, more energy cost
Reformer Pressure	200-450 psig	Lower P → more conversion (Le Chatelier)
HT Shift Temp	600-750°F	CO + H2O → CO2 + H2 (Fe-Cr catalyst)
LT Shift Temp	375-500°F	Additional CO conversion (Cu-Zn catalyst)

Process Configurations

SMR (Steam Methane Reforming): most common — CH4 + H2O → CO + 3H2 (endothermic, fired heater)
ATR (Autothermal Reforming): partial oxidation + reforming — O2 + CH4 → CO + 2H2 (adiabatic)
Shift Conversion: CO + H2O → CO2 + H2 (HT shift → optional LT shift)
H2 Purification: PSA (pressure swing adsorption) — 99.9%+ H2 purity

Products & Yields

Hydrogen: 99.9-99.999% purity (from PSA)
PSA tail gas: low BTU fuel (H2, CO, CH4, CO2) — burned in reformer
Steam: export steam from waste heat recovery (significant quantity)

Common Troubleshooting

Low H2 production: check reformer outlet T, S/C ratio, catalyst activity
High methane slip: insufficient reforming — check tube temps, catalyst
PSA performance: adsorbent aging, valve leaks — check H2 recovery and purity
Reformer tube hot spots: flame impingement, catalyst maldistribution, coking
Shift catalyst issues: low activity, sulfur poisoning, temperature excursion

Source: Process_Tech_Quick_Reference_Cards_v1.xlsx · sheet “Hydrogen”

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