Evaluation of on-site hydrogen generation via steam reforming of biodiesel: Process optimization and heat integration

•Heat integrated fuel processor concept for biodiesel steam reforming (50 Nm3/h H2).•Maximum system efficiency of 75.6% derived at S/C = 2.53.•Net hydrogen production costs range from 5.77 €/kg to 11.15 €/kg.

The present simulation study investigates on-site hydrogen generation (50 Nm3/h) via steam reforming of biodiesel. The system comprises a steam reformer, a water gas shift stage, a pressure swing adsorption unit and a dual fuel burner. Sensitivity analysis with Aspen Plus shows a positive effect on overall system efficiency for high pressure and low steam-to-carbon ratio. A theoretical maximum efficiency (based on lower heating value) of 78.2% can be obtained requiring a complex and costly heat exchanger network. Consequently, a system simplification is proposed resulting in a novel fuel processor concept for steam reforming of biodiesel based on a fully heat integrated system. A thermal system efficiency of 75.6% is obtained at S/C = 2.53, p = 13 bara and T = 825 °C. The techno-economic evaluation reveals hydrogen production costs ranging from 5.77 €/kg to 11.15 €/kg (depending on the biodiesel market price).