World Scale Hydrogen Production
Dr Vince White
Senior Research Associate Air Products
Hersham Place Technology Park
Molesey Road – Walton-on-Thames - UK
IMechE/IChemE Evening Seminar: 2019 Hydrogen event
Birdcage Walk, 7th March
Presentation by
1
Agenda • Air Products
• Hydrogen production from Steam Methane Reformers (SMRs)
• CO2 capture from SMRs
- Options and Port Arthur Project
• Autothermal Reformers (ATRs) and Gas Heated Reformers (GHRs)
• Gasification
• Hydrogen Pipelines
• Vehicle Fuelling
2IMechE/IChemE Evening Seminar: 2019 Hydrogen event
Air Products Today
$8.9billion in sales
~16,000employees
50+countries
~$35Bmarket cap
7+decades in business
170,000+customers
1,800miles of industrial
gas pipeline
750+ production facilities
30+industries
served
IMechE/IChemE Evening Seminar: 2019 Hydrogen event
Production of Hydrogen 1 - SMRProcess Characteristics
- External heating of a catalytic reactor
- Combustion products vented to atmosphere
- 40% of CO2 emissions from combustion
- 60% from “shifted”syngas
- CO2 removal from syngas less expensive than from flue gas
50,000 Nm3/hr
Steam Natural
Gas Reformer
IMechE/IChemE Evening Seminar: 2019 Hydrogen event
Tarragona, Spain66 kNm3/h
Mantova, Italy17 kNm3/h
Cressier, Switzerland8 kNm3/h
Catlettsburg, Kentucky37 kNm3/h
Air Products builds and operates hydrogen plants of all sizes, from <1 kNm3/h to >170 kNm3/h,
tied to pipelines or as standalone “on-site” facilities
5
Chengdu, China100 kNm3/h
Norco, Louisiana>170 kNm3/h
IMechE/IChemE Evening Seminar: 2019 Hydrogen event
SMR schematic
NG in
Convection section
Sulfur removal
Reformer boxWGS reactor
Heat exchangers
PSA vessels
H2 product
6IMechE/IChemE Evening Seminar: 2019 Hydrogen event
Decarbonised Hydrogen:CO2 removal from SMR – 3 options
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Port Arthur CO2 ProjectCO2 capture from syngas by CO2 VSA – Option 1
IMechE/IChemE Evening Seminar: 2019 Hydrogen event
Air Products’ Port Arthur CO2 Project New technology to recover anthropogenic CO2 for EOR
• Retrofit of 2 Steam-Methane Reformers (SMR) located in the middle of a refinery
• Capture and purification of CO2 from hydrogen plants (see previous slide “Option 1”) for EOR
• Technology developed by Air Products
• 90%+ capture of CO2 from syngas
• ~2600 t/d (50 MMSCFD) of CO2 to Denbury’s Green Pipeline for West Hastings oilfield
• 30 MWe cogeneration unit to generate power and make-up steam
• Full capacity achieved April 2013
• 1x106 tonnes of CO2 captured by April 2014
• 4x106 tonnes of CO2 captured by Oct 2017
H2Power Generation
CO2 Removal, Purification,Compression
CO2 Transport & Storage
H2Power GenerationExport Steam
H2Power Generation
CO2 Removal, Purification,Compression
CO2 Transport & Storage
H2Power GenerationExport Steam
CO2 VSA Technology
CO2 VSA Technology
Dehydration
Compression
Cogeneration
H2, Power
H2, Power, Steam
CO
2
Pip
eline
IMechE/IChemE Evening Seminar: 2019 Hydrogen event
Wet CO2
Syngas (CO2 Removed)Syngas
Export CO2
Wet CO2
Syngas (CO2 Removed)Syngas
Existing Stream
PORT ARTHUR 2
PORT ARTHUR 1
Simplified CO2 Capture Block Flow Diagram
New Stream
Revised Stream
Natural Gas
Power Export
ExportHydrogen
Syngas
Natural Gas
Power Export
ExportHydrogen
Syngas
Utilities
HP Steam Export
Purge GasEXISTING SMR EXISTING PSA
Utilities
HP Steam Export
Purge GasEXISTING SMR EXISTING PSA
NEWCOMPRESSOR / DRIER
NEW VSACO2H2
CO2H2 NEW VSA
IMechE/IChemE Evening Seminar: 2019 Hydrogen event
Key Project ComponentsCapturing CO2 for Denbury’s “Green Pipeline”• Vacuum swing adsorption (VSA) vessels
• Tri-ethylene glycol (TEG) drier system
• CO2 export compressor
- 8 stages
- Export pressure over 2000 psig (~140 bar)
• 13 mile (21 km) CO2 Pipeline connecting to Denbury’s “Green” 300+ Mile (~500 km) CO2 Pipeline
Map shows Denbury’s Green CO2 Pipeline. Data source is Denbury, December 2011, CO2 Flooding Conference
10 IMechE/IChemE Evening Seminar: 2019 Hydrogen event
Production of Hydrogen 2 – POX & ATRProcess Characteristics
- Pressurised reactors with heat supplied by direct reaction with oxygen
- No venting of combustion products- All CO2 available for capture at pressure
Partial Oxidation Autothermal Reformer
Natural Gas
Oxygen Steam
Natural Gas
Oxygen POX
Catalyst
IMechE/IChemE Evening Seminar: 2019 Hydrogen event
12IMechE/IChemE Evening Seminar: 2019 Hydrogen event
Johnson Matthey’s ATR/GHR improves on ATR by using high temperature H2/CO/CO2
syngas to heat a convective reformer
source: Johnson Matthey
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Euro Cent/Nm3
18.9 15.7 14.5
Johnson Matthey’s comparison of levelized cost of hydrogen, with 95% CO2 capture
Cost of H2 at 95% capture equivalent to just capturing process CO2 from SMR, 56% capture
source: Johnson Matthey
Gasification
IMechE/IChemE Evening Seminar: 2019 Hydrogen event
Leading Global HydrogenPipeline Positions
Corunna
Suncor
ST.CLAIR RIVER
SarniaCanada
40
ShellRefinery
15 Air Products Confidential
Geismar
Convent
Cosmar
Taft
Geismar
Chalmette
BPCarson
ShellWilmington
Conoco PhillipsWilmington
Conoco Phillips Carson
Wilmington H2
ValeroWilmington
Gulf Coast
Mont Belvieu
Port Arthur
Bayport
Battleground
Pasadena
City of Houston
610
Lake CharlesBeaumont
Texas
10
45
Gulf of Mexico
Geismar
Lake Pontchartrain
Convent
Cosmar
Taft
Nola
NewOrleans
Louisiana10
Plaquemine
~ 112 Mi.
Baton RougeTesoroCarson
TesoroWilmington
DominguezChannel
Phillips 66Wilmington
Phillips 66 Carson
Carson H2
Wilmington H2
1
SouthernCalifornia
ValeroWilmington
SF BayRefineries
710
405
110
91
405
Edmonton
Fort Saskatchewan
Suncor
Imperial Oil
Sherritt
Sturgeon County
Strathcona County
ShellWilliamsAlberta,
Canada
825
15
825
16
16
Gulf of Thailand
BIG #2
BIG #1
Map Ta Phut, Thailand
H2
Maasvlakte
GOX
H2
CO
Rosenburg
Rotterdam
Pernis
Zwijndrecht
Rotterdam, Netherlands
H2
COSyngas
Air Products Canada
Luling
Garyville
Norco110
Air Products HyCO facilities
H2 pipeline
CO pipeline
Syngas pipeline
To Freeport
Baytown
Texas City
LaPorte
Hydrogen Fueling
• Unique product offerings for H2 fueling
• Projects since 1993
- 225 hydrogen station projects
- 1,500,000 fuellings/yr
- ~7 million fuellings total
- Stations in 20 countries
- 50+ patents
- SAE J2601 Fueling Standard based on AP technology
16 IMechE/IChemE Evening Seminar: 2019 Hydrogen event
Summary
• Large scale hydrogen production from steam methane reforming is widely practised
• CO2 capture from SMRs is possible and demonstrated, but ATRs are better suited to high levels of CO2 capture
• Piping hydrogen is well understood: 100s miles of hydrogen pipelines around the world, connecting dozens of hydrogen plants with many customers
• Gasification (of bottom of the barrel, petcoke, coal) could play a part in a hydrogen-with-CO2-capture world, even in the UK
17IMechE/IChemE Evening Seminar: 2019 Hydrogen event
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18Air Products Industrial Gases Technology Symposium
