Conventionally, hydrogen is produced by the steam methane reforming (smr) process by using natural gas as a feed stock. however, smr process is proved to be energy consuming for the production of ammonia worldwide. the fertilizer industries which are using smr process, faces a problem of high energy consumption in their plants. to reduce the energy consumption in the existing ammonia plant, in this paper two modifications have been proposed. the first proposed modification is use of reformer stack gas heat by employing the organic rankine cycle (orc) in the downstream of the convection bank of the reformer to recover the heat contained within the reformer stack gases before it leaves to the atmosphere. for the orc process, hfc-245fa – a low boiling fluid has been used for waste heat recovery. in this paper the employment of orc in the existing plant has been shown with figures and to show the energy savings data, aspen simulation data are also included. to come to the conclusion, the costing analysis is included for the proposed modification, which showed a good energy savings of more than 85 lacs with power generation ranging between 74 kwh to 200 kwh. the second proposed modification is use of newer medium temperature shift (mts) catalyst for the co shift conversion of the reformed gas. however, the use of mts catalyst requires several modifications in the existing plant. it has been observed that use of mts catalyst in the downstream of autothermal reformer (atr) proves to be energy conserving. the paper includes the comparison of mts catalyst with existing high temperature shift (hts) catalyst with reference to operating parameters. the design of combined smr-atr plant, to use mts catalyst has been included in this project, which ultimately helps in reducing the energy consumption and increasing the hydrogen production. all the data shown in the project are taken on the basis of several assumptions and no particular data of any existing plant has been included.