Performance analysis of a novel SMR process integrated with the oxy-combustion power cycle for clean hydrogen production

The steam methane reforming (SMR) process has been instrumental in industrial hydrogen production, despite its high carbon footprint. The direct capture of CO₂ from its flue gas remains a challenge. In this study, we propose a hybrid SMR process integrated with the NET Power Cycle (NPC) to repurpose exhausted CO₂ and produce supercritical CO₂ directly. To simulate the conventional SMR process, we developed mathematical and machine-learning models to predict hydrogen production. The integration of heat between the SMR and NPC units led to 40 % reduction in natural gas consumption, while the energy required for CO₂ capture was reduced by 54 %. The optimization of the SMR-NPC process was conducted using the genetic algorithm (GA), resulting in low direct CO₂ emissions of 0.6 kg-CO₂/kg-H₂ and levelized cost of hydrogen (LCOH) of $3.39/kg-H₂. The novel process proposed in this study offers an efficient means to enhance both the economic and environmental performance of industrial hydrogen production.