Modelling and Scale-Up Studies of Sorption-Enhanced Steam Reforming (SE-SR) of Methane for Blue Hydrogen Production

Udemu, Chinonyelum

Abstract

Rising concerns over climate change, largely driven by anthropogenic CO2 emissions, have intensified research and development in low-carbon and carbon-neutral energy solutions. Hydrogen is increasingly gaining attention. Unlike fossil fuels, hydrogen combustion produces only water vapor, making it an environmentally attractive fuel source. This potential has spurred technological innovations in hydrogen production methods. Sorption-enhanced steam reforming (SE-SR) of methane is an emerging technology incorporating in-situ carbon capture that enables hydrogen (blue) production from natural gas. This study aims to advance this approach through mathematical modelling and scale-up within bubbling fluidised bed reactors. This is significant because SE-SR currently has a low technology readiness level (TRL). The aim was achieved by developing novel reactor and process models in Barracuda Virtual Reactor® and Aspen Plus® software, respectively, as well as applying scaling laws and methodologies to upscale SE-SR of methane for industrial applications.
A computational particle fluid dynamics (CPFD) reactor model was developed using Barracuda VR® and rigorously validated against experimental data from the literature. Comparisons showed close agreement, with deviations between simulated and literature values falling within a narrow range of 0.1-2%. The validated CPFD model was then employed to evaluate the reliability of two potential scale-up methodologies. One of the methodologies was later selected for scaling simulations, due to better preservation of hydrodynamic behaviours and chemical conversion rates at more conserved materials and reactor dimensions. It was applied, in conjunction with the CPFD model, to progressively upscale the SE-SR reactor - first from a bench-scale reactor to an industrial-sized 1 MWth unit, then further to commercial-scale reactors of 50 MWth and 150 MWth. This effort establishes a validated simulation-guided approach for methodically upscaling SE-SR reactor from bench-scale to full commercial scale.
Furthermore, the economic scalability of SE-SR was also evaluated. A rigorous process simulation in Aspen Plus® software and cost assessment was conducted comparing projected levelised cost of hydrogen (LCOH) for scaled-up SE-SR systems against more established blue hydrogen alternatives, including autothermal gas-heated reforming coupled with carbon capture and storage (CCS), as well as conventional steam methane reforming plus CCS. The analysis found SE-SR to have a competitive economic outlook at the 600 to 1000 MWth commercial scale assessed. This benchmarking suggests SE-SR can be scaled cost-effectively for industrial applications. As the technology continues to mature, capital requirements may see further reductions. SE-SR therefore demonstrates strong potential as an economically viable pathway to facilitate large-scale production of low-carbon hydrogen.

Citation

Udemu, C. (2024). Modelling and Scale-Up Studies of Sorption-Enhanced Steam Reforming (SE-SR) of Methane for Blue Hydrogen Production. (Thesis). University of Hull. https://hull-repository.worktribe.com/output/5086126

• Thesis Type: Thesis
• Deposit Date: Mar 20, 2025
• Publicly Available Date: Apr 8, 2025
• Public URL: https://hull-repository.worktribe.com/output/5086126
• Additional Information: School of Engineering; University of Hull
• Award Date: Oct 15, 2024