As one of the most promising clean energy carriers of the 21st century, hydrogen is accelerating the global energy transition. Among the various hydrogen production technologies, Steam Methane Reforming (SMR) dominates industrial hydrogen production due to its maturity, economic viability, and scalability. Global hydrogen production reaches approximately 97 million tonnes annually, with over 70% derived from fossil sources – and SMR stands as the undisputed workhorse of this sector.
Building on decades of global industrial experience, GeneralFlame has developed a highly efficient, stable, and reliable SMR process package. Using natural gas and demineralized water as feedstocks, the system produces high-purity industrial hydrogen while maximizing waste heat recovery and generating steam as a byproduct.
I. Process Flow
GeneralFlame SMR process consists of four core stages:
1. Feedstock Pretreatment (Desulfurization + Preheating)
Natural gas feedstock first enters the pretreatment unit, where deep desulfurization is performed using CoMo/ZnO catalysts to effectively remove sulfur compounds – catalyst poisons that would otherwise deactivate the reforming catalyst. The desulfurized feed gas is then preheated to the required reaction temperature.
2. Steam Reforming Unit (Core Hydrogen Production Reaction)
The preheated natural gas reacts with steam over a Ni-based catalyst at high temperatures of 700–1,000°C. The primary reaction is: CH₄ + H₂O ⇌ CO + 3H₂. This strongly endothermic reaction is typically operated at 800–900°C and 1.5–3.0 MPa in industrial practice.
3. CO Shift Conversion Unit (Hydrogen Yield Enhancement)
The reformed gas contains carbon monoxide (CO), which is further reacted with steam via the Water-Gas Shift (WGS) reaction to produce additional CO₂ and H₂: CO + H₂O → CO₂ + H₂. This step significantly increases hydrogen yield while reducing CO concentration to below 1%.
4. Product Purification Unit (Hydrogen Upgrading)
The shifted mixed gas enters the Pressure Swing Adsorption (PSA) unit for separation and purification. The PSA unit selectively adsorbs impurity gases and releases high-purity hydrogen, achieving product purity of 99.9% . The purification process involves no chemical consumption, offers flexible operation, and features a high degree of automation.
II. Core Features
✅ Proven Technology, Globally Validated
SMR is the most mature hydrogen production technology in global industrial application, accounting for 95% of the industrial hydrogen market. GeneralFlame SMR process is built on decades of engineering expertise, ensuring stable and reliable plant operation.
✅ High Efficiency, Controllable Energy Consumption
GeneralFlame SMR process achieves total system efficiency of >75% , ranking among the industry's best. Through deep waste heat recovery, energy utilization efficiency is further enhanced with controllable consumption.
✅ Well-Defined Catalyst System
- Reforming catalyst: Ni-based – high activity, excellent selectivity, significant cost advantage
- Desulfurization catalyst: CoMo/ZnO – high desulfurization efficiency, long service life
✅ Stable Operating Pressure, Broad Applicability
Operating pressure of 1.5–3.0 MPa makes the system adaptable to a wide range of downstream applications including chemical plants and hydrogen refueling stations.
III. Typical Applications
GeneralFlame SMR process is widely applicable to:
- Refinery hydrotreating: Supplying high-purity hydrogen for oil refining
- Ammonia and methanol production: Meeting chemical feedstock hydrogen demand
- Industrial park central hydrogen supply: Enabling regional hydrogen distribution
- Hydrogen refueling stations: Supporting the fuel cell vehicle ecosystem
IV. Conclusion
GeneralFlame SMR hydrogen production technology delivers a reliable, economical, and scalable hydrogen solution for industrial users – built on a mature technical pathway, efficient energy utilization, well-defined catalyst systems, and stable operating pressure. As the hydrogen industry continues its rapid expansion, GeneralFlame remains committed to creating value for customers and supporting the global low-carbon transition.
