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Raccoon Mountain Team
Hydrogen Production
Proposal
4-22-98
Outline Problem Statement Flow Diagram Material Balance Equipment Design Economic Analysis Final Proposal
Problem Statement
To design a plant which produces a required amount of hydrogen while minimizing costs and waste streams.
(Rev.3//2-26-98)
Flow Diagram
Desulphuriser Reformer
Heat
Natural Gas
Water
Heat
Desulphuriser Passed over ZnO at 675-750 oF
Primary Reformer Ni catalyst at 1300-1500 oF
Flow Diagram
HighTempShift
H2 (g)
CO2 (g)
PSASystem
CO (g)
HiTemp Shift Fe3O4 catalyst at 650-850 oF
PSA (Pressure Swing Adsorption) System 5 packed w/ molecular sieve adsorbent.
Heat Exchangers (2)
Material Balance (Target)
45%
55%
CH4 + 2H20 --> CO2 + 4H2
CH4 + H20 --> CO + 3H2
CH4 = 1.4 H20
94% completion
5 MW =139000 lbmol H
CO + H20 --> CO2 + H2
Reformer
HiTemp Shift
Equipment Design
Economic Analysis
Reactor 100K gal. stainless steel $215,000
Economic Analysis
Hi Temp Shift Tank 100K gal. stainless steel $175,000
Economic Analysis
PSA System Tank (5) 500 gal. stainless steel
(300psi) $245,000
Economic Analysis Storage Tank (2)
50K gal. 304 stainless steel $120,000
Heat Exchangers (2) 304 Stainless steel w/.75” ODx1in. 1000ft2 area $35,000
Economic Analysis
34%
18%
13%12%
10%
7%
3%
3%
Purchased Equipment $790,000 Service Facilities $434,500
Installation $308,100 Instrumentation $276,500
Piping $244,900 Buildings $173,800
Electrical $79,000 Land $63,200
Economic AnalysisRunning Total $1,580,000
(Direct Plant Costs)
Engineering/Sup. (32%) $252,800 Construction (34%) $268,600
Subtotal $2,101,400
(Direct and Indirect Costs)
Contractor’s Fees (5%) $105,070 Contingency (10%) $210,140
Fixed Capital Investment $2,416,600
Economic Analysis COSTS
$3.50 / 1000cu.ft Natural Gas
$0.45 / 1000gal. H2O
$0.0758 / kwh Electricity
PROFITS
$0.40 / 100cu.ft Hydrogen Gas
Carbon Monoxide
Carbon Dioxide
Economic AnalysisFixed Capital Investment $2,416,600
Estimated Monthly Expenses $9,213,000
Estimated Monthly Profit $9,732,000
Estimated Yearly Profit $6,228,000
Estimated Recovery Period 10 months
Proposal
Economic Analysis
-$2,500
-$2,000
-$1,500
-$1,000
-$500
$0
$500
NOTE: Profits x103
Conclusion