Intensification of natural gas reforming: Feasibility assessment of a novel technology for blue hydrogen production

Hydrogen stands at the forefront of the energy transition, yet its conventional carbon- and energy-intensive natural gas reforming production highlights the need for more sustainable solutions. This study presents a novel intensified concept that integrates steam methane reforming with calcium looping for in situ CO₂ capture and high-purity hydrogen production at a low reforming temperature (600 °C), along with chemical looping of nickel oxide to provide internal heat during regeneration of the CO₂ capture material. Setting the levelized cost of hydrogen production over a 20-year lifetime as a comparative key metric, reveals that the intensified process outperforms conventional natural gas reforming, costing $3.61 per kg versus $3.77 per kg. Additionally, the intensified process attains ∼85% reduction in carbon emissions by eliminating fossil fuel combustion to drive reforming via the exothermic carbonation reaction and separating the by-product CO₂ into a high-purity stream. Consequently, a generalized carbon tax of 120$ per tonne of emitted CO₂ could raise costs more than 35% for conventional reforming, while its impact on the intensified process is significantly lower. Overall, the demonstrated feasibility of the novel reforming technology establishes a scalable, cost-competitive, and low-carbon pathway for hydrogen production, while emphasizing the transformative potential of process intensification strategies.