Abstract
This study presents a method for the synthesis and optimization of an integrated onsite hydrogen production and associated supply chain network for petroleum refinery plants that utilize grey, blue, and green hydrogen to meet operational demand. The primary objectives are to minimize carbon emissions and total annual cost (TAC). The study formulates the problem as a Mixed Integer Nonlinear Programming model using General Algebraic Modelling System, aiming to balance economic and environmental objectives. The goal is to identify the optimal production mix and hydrogen supply chain that achieves the lowest possible carbon footprint while maintaining cost efficiency. In the cost-minimization scenario, the optimal production mix consisted of 80 % steam methane reforming (SMR) and 20 % SMR with carbon capture (SMRCCS), resulting in the lowest TAC of $ 0.88 × 106. In contrast, the emission-minimization scenario favoured a mix of 80 % electrolysis and 20 % SMRCCS, achieving the lowest CO2 emissions at 0.0123 t/y. A balanced, multi-objective optimization with equal weighting between cost and emissions reduced emissions by 37.34 % compared to the cost-optimal case, highlighting the potential for substantial environmental benefits with moderate cost trade-offs. This framework supports refineries in transitioning to sustainable hydrogen production.
