Design and Simulation of Hydrogen Production from Diesel Reforming for Fuel Cell Applications

Hydrogen production encounters significant challenges in transportation and storage, such as leakage, transit safety, and the need for efficient storage conditions. on-site production through diesel fuel reforming presents a promising solution due to diesel’s affordability, availability, and ease of transport. however, sulfur and carbon monoxide in diesel must be removed to protect the catalysts involved in the process. this study designs a conceptual process for reforming sulfur-containing diesel to generate 300 kw of electricity in a fuel cell system using the douglas method, which structures chemical process design into a decision hierarchy. it starts with the input-output structure, summarizing the process by detailing input and output streams based on designated design variables. the recycle stream structure further divides the process into reactor and separation sections, each incorporating defined recycling flows. finally, the overall separation section structure integrates gas and liquid recycling systems, providing a comprehensive strategy for separation unit design. the process flow diagram (pfd) was initially developed and subsequently analyzed in detail through simulation using aspen hysys software. the results indicate that producing 300 kw of electricity requires 17 kg/h of pure hydrogen, which necessitates 47 kg/h of sulfur-free diesel. overall, 60 kg/h of diesel is needed. future research should focus on optimizing sulfur removal, reducing carbon monoxide levels, enhancing the water-gas shift reaction, maximizing energy efficiency, and assessing economic viability, including roi and payback period.