PTQ Q2 2026 Issue

by the ratio of feed to the purity of oxygen in the integration of combustion in the SMR unit.

Total heat content of flue gas/flow rate in steam methane reformer at case study in refinery

In this case, we found that the oxygen content of the flue gas should ideally not exceed 4%, which means that the SMR’s combustion unit is at an optimum level to increase effi - ciency. Additionally, efficiency can be increased with a higher heat value of the flue gas. These results can be applied across different industry sectors to support the efficiency of the boiler system and all combustion units. Conversion of flue gas heat loss to power Table 2 Lambda SR, kg/kg

Content of flue gas

Remarks

Proportion oxygen in flue gas, %

3.51% in operating condition

1.00 1.11 170

Specific heat flue gas, kJ/(m³∙°C) Temperature of flue gas, °C

Ambient temperature, °C

Stoichiometrically quantity of flue gas, kg/kg, SR

11.0 0.31 10.5 11.0 1.05

V 0 = 0.28 * LHV

L ₀ = 0.26 * LHV + 0.25 V f g = V ₀ + ( l – 1 ) * L ₀

Stoichiometrical quantity of air, kg/kg, SR

Specific flue gas flow, kg/kg

AR is the ratio, kg/kg, of fed air to fuel

combustion (ER ≥1).

Steam methane reformer heat loss and conversion to power with ORC process at value

Overall, the conversion of heat loss from flue gas to power through the ORC process presents a sustainable solution for industries to utilise waste heat effectively.7 The case study results in Table 3 show that heat loss from the SMR flue gas is 1,185 ton/h, which corresponds to 20,115 MWth at a 250°C outlet temperature in the flue gas pipeline. The ORC power can be produced from reformer heat-loss recovery, and with heat loss from the flue gas is equal to 4.8 MWele. Moreover, the results of Table 3 are presented as follows: • The heat loss recovery in one refinery unit can be equal to one power plant supplying about 5 MWele without any combustion unit of boilers. • The heat loss recovery of flue gas and reformers can reduce GHG emissions to approximately 40% of the total CO₂ in one unit of the refinery. • The increase in H₂ with ZCT Solutions technologies by the heat-loss recovery system covers about 40% of the H2 requirement needed in refinery processes.8 Conclusion This case study highlights optimisation by heat-loss recov - ery associated with refinery SMRs. Thus, refineries can not only reduce GHG emissions but also transition to greener energy processes, aligning with global sustainability targets. SMR reactor optimisation through proprietary tech- nologies and heat integration is crucial for enhancing the efficiency and environmental sustainability of indus - trial processes. By recovering heat losses and converting them into power using technologies like ORC, significant improvements can be made in reducing fuel consumption, minimising carbon emissions, and increasing hydrogen production in refineries. This innovative approach not only enhances the perfor - mance of SMR reformers but also paves the way for green refining practices, aligning with global sustainability goals.

Heat loss and ORC values Heat loss in flue gas, Ton/h) Heat loss in flue gas, MWth

Amount 1,185.12

20,115

ORC flow rate in heat exchanger, m³/h

734.6

ORC cp

2.10

ORC Power, MWele

4.8

Table 3

References 1 Sinaei Nobandegani, M., Sardashti Birjandi, M.R., Darbandi, T., Khalilipour, M.M., et al., An industrial steam methane reformer optimi- sation using response surface methodology , 2016;36. 2 Zečević, N., Bolf, N.. Integrated method of monitoring and optimisa- tion of steam methane reformer process , 2020;8. 3 Kumar, A., Baldea, M., Edgar, T.F., Real-time optimisation of an indus- trial steam-methane reformer under distributed sensing , 2016;54. 4 Zhang, H., Fan, F., Multiobjective optimisation of steam methane reformer in micro chemically recuperated gas turbine, 2024. 5 Cherif, A., Nebbali, R., Lee, C-J., Design and multiobjective optimi- sation of membrane steam methane reformer: A computational fluid dynamic analysis, 2022;46. 6 Quirino, P.P.S., Amaral, A.F., Manenti, F., Pontes, K.V., M apping and optimisation of an industrial steam methane reformer by the design of experiments, (Doe) 2022;184. 7 Simakov, D.S.A., Sheintuch, M., Model‐based optimisation of hydro - gen generation by methane steam reforming in autothermal packed‐ bed membrane reformer, 2011; 57. 8 Mirvakili, A., Hamoudi, S., Jamekhorshid, A., Gholipour, M.J., Karami, R., CFD simulation and optimisation of turning different waste gases into energy in an industrial steam methane reformer, 2023;147. Nabeel Ataimisch is Head of Process Engineering and COO of ZCT Solutions in Vienna, focusing on the development of future technol - ogies and ideas, especially biomass and gas for industrial sites treat- ment and optimisation, as well as the optimisation of refineries and petrochemical plants. He completed his studies in chemical engineer- ing at the University of Technology in Vienna. Ataimisch holds numer - ous patents, including Patent Nr. 516273_EU_Austria ‘Method and plant for the treatment of combustion exhaust gas’.

The author would like to thank Ronald Bauer, CEO and owner of the company.

PTQ Q2 2026