Steam methane reforming is extensively being used for synthesis gas as well as hydrogen gas production throughout the world. Hydrogen is used in chemical and refining industry and is expected to play a future role as potential fuel. More than 51% of hydrogen produced in the world is used in ammonia and methanol production, and remaining for hydotreating in refineries and hydrogenation. Thus it suggests increased investment on the development of sustainable and energy efficient primary reformer design.

Primary reformer is one of the most critical and energy intensive section in ammonia plant. Major components of reformer design include catalytic tubular reactor design, refractory wall of furnace and heat recovery at convection section of the primary reformer. Paper presents the design constraints and its optimum solution for tubular reactor following optimum steam to carbon ratio in the feed of reformer. Results are compared with process simulation using aspen Hysys plus V9. Design limitations and catalyst sensitivity to design and operational key parameters are discussed.It was found that major operational problems including catalyst tube failure, methane leakage in the outlet stream and catalyst poisoning can be mitigated by carefully controlling the steam flow in gas feed, furnace draught, and reformer outlet temperature.