AWARDSSHORTLIST
PV MATERIALS ENABLING AWARD
A further disadvantage of electrolysis is higher CO2 emissions unless the electricity comes from a renewable source. Compact, standardized, modular SMR plants provide the benefit of onsite hydrogen production at low cost while eliminating compression and transportation costs.
HYOS-R 10k: Onsite hydrogen generation
What challenge does this process address?
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Silicon manufacturing requires considerable amounts of hydrogen. The product addresses the handicap of today’s hydrogen infrastructure, where hydrogen is produced in a small number of large centralized plants and distributed via truck or pipeline. The technology of choice to produce low cost hydrogen is Steam Methane Reforming (SMR).
Hydrogen distribution by truck requires compression/liquefaction and is inefficient and costly. Hydrogen pipelines are expensive to built and difficult to obtain regulatory approval for. Unless, the PV plant is located next to an existing large SMR plant or pipeline, hydrogen can be very expensive.
How do you meet the challenge? Onsite production provides an alternative to centralized hydrogen generation and truck distribution. Onsite technologies available cover the hydrogen needs of typical Silicon PV lines have been limited. Electrolysis has very high operating costs compared to SMR.
What is particularly noteworthy? Cost, utility consumption, footprint, and start-up time have been greatly reduced for this compact SMR compared to standard industrial practice, through an efficient catalyst and break through design and compact integration of individual components. In addition, onsite hydrogen production generates up to 40% less CO2 emissions compared to traditional modes of supply by truck, especially if liquid hydrogen is supplied.
Please explain the process The process steps required to produce high purity gaseous hydrogen from a natural gas stream are summarized as follows: Natural Gas Feed Pressurization Natural Gas Feed Desulphurization Steam-Hydrocarbon Reforming Water-Gas Shift Conversion Waste Heat Recovery and Steam Generation
Hydrogen Purification
Natural Gas (NG) is compressed to 350 PSIG, preheated to 750o
F and
passed over a bed of zinc oxides to remove any hydrogen sulfide that is present. Sulfur free NG (
The hydrocarbons and steam react over the catalyst, to produce hydrogen and carbon oxides by the following equations: [1] CnHm (g) +nH2O (g) + Heat = nCO (g) + (m/2+n)H2 (g)
[2] CO(g) + H2O(g) = CO2 (g) + H2 (g) + Heat
Our proprietary catalyst allows for the reformer reaction to be carried out at much lower temperatures than conventional SMR technologies. This results in less NOx production and less thermal stress on the catalyst tubes, providing environmental and reliability benefits over conventional SMR technologies. The reformer gas exiting the tubes will consist of H2, CO, CO2,
2. Flexibility
By installing several units the hydrogen generation capacity can be adjusted to match requirements allows low-cost incremental capacity additions. Allows optimum allocation of capital for projects that have ramp-up phases stretching over several years and the possibility to relocate assets if demand switches.
3. Lower emissions
Consistent production of high purity hydrogen with lower carbon footprint.
CH4
and H2O. The process gas stream exiting the reformer enters the shift converter where additional hydrogen is generated through the reaction: [3] CO (g) + H2O (g) = CO2 (g) + H2 (g) + Heat. The gases are cooled in subsequent processes and the process gases are sent into the PSA purification system where H2 is separated from the other molecules to produce purified H2.
How does it go beyond current solutions? Technical inventions applied in the design of the units include: reformer design and metallurgy, the Pressure Swing Adsorption (PSA) purification system, and a sulfur tolerant reformer catalyst. These three areas of innovation are packaged in a compactly manufactured skid with a small footprint.
1. Lower hydrogen costs through lower Capex and Opex
Standardization of skidded, modular plants lead to lower capital and installation costs. Plants are fully assembled and tested before shipment which greatly reduces installation time and cost. High efficiencies are achieved with integrated steam generation and waste heat recovery and the use of a proprietary catalyst. The customer benefits from the advantages of onsite production while eliminating compression or liquefaction and transportation costs.
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www.solar-pv-management.com Issue V 2010
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