Sensitivity AnalysisBased Simulation and Optimization of SteamMethane Reforming in Aspen Plus for Improved HydrogenProduction

Abstract

Rising demand for clean energy has increased interest in hydrogen as a sustainable energy carrier due to its high energy content and low emissions. Steam methane reforming (SMR) remains the dominant industrial production method because of its efficiency and economic viability. This study simulates hydrogen production via SMR using Aspen Plus to evaluate reactor performance and operating parameters. The process includes steam generation, reforming reactions, separation, and recycle streams under steady-state conditions. The reformer is modeled using an equilibrium (RGibbs) reactor with the PRSK equation of state. Sensitivity analysis shows that increasing temperature enhances hydrogen yield due to the endothermic reaction, while higher pressure reduces hydrogen production because of equilibrium constraints. Increasing the steam-to-carbon ratio improves methane conversion, though gains diminish at high steam levels. Optimal conditions involve high temperature, low pressure, and moderate steam ratio, producing a hydrogen-rich stream with minimal unreacted methane.