The refining process produces Heavy fuel oil (HFO) which brings substantial barriers during utilization because it contains complex molecules and costs a lot to process while causing major environmental stress. The usage of HFO through combustion processes produces extensive carbon dioxide pollution that impacts climate change as well as harmful emissions derived from sulfur components and nitrogen chemical compounds and heavy metals found in the fuel. Investigating hydrogen production through thermochemical conversion of HFO serves as a sustainable fuel upgrade method for clean versatile hydrogen production. The research investigates two processing concepts: Case 1 considers standalone HFO gasification for hydrogen generation alongside Case 2 that merges HFO gasification with steam methane reforming (SMR) to increase thermal efficiency in hydrogen production. The analysis included process modeling through Aspen Plus® software simulation combined with comprehensive technical and economic assessments. The integration of waste heat from gasification with SMR through Case 2 processes improves the system by effectively driving endothermic reactions. The technical assessment shows that Case 2 outperforms Case 1 by obtaining improved cold gas efficiency along with enhanced overall energy efficiency which results in higher hydrogen output from each feedstock unit. The new design of Case 2 lowers total capital expenses per hydrogen production ton by 25% while boosting the net present value (NPV) by 30%. The integrated process approach of Case 2 delivers hydrogen at a lower levelized cost of hydrogen (LCOH) than existing industrial standards which strengthens its market competitiveness.
