Report No. 32 HYDROGEN. December A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE PARK, CALIFORNIA

Transcription

1 Report No. 32 HYDROGEN by RICHARD G. DENNEY December 1967 A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE I I MENLO PARK, CALIFORNIA

2 CONTENTS INTRODUCTION.... SUMMARY INDUSTRY STATUS... CHEMISTRY OF HYDROGEN PRODUCTION. Catalytic Steam Reforming of Hydrocarbons... Partial Oxidation of Hydrocarbons Decomposition of Hydrocarbons.. Carbon Monoxide Shift Conversion. Other Reactions... HYDROGEN FROM STEAM REFORMING OF HYDROCARBONS... Catalytic Steam Reforming of Natural Gas... Review of Processes... Reformer Catalyst... Reformer Feed... Reformer Conditions... The Reformer Furnace... Process Description... Process Discussion... Cost Estimates... Capital Costs... Production Costs... Catalytic Steam Reforming of Naphtha... Review of Processes... Process Description... Process Discussion... Cost Estimates... Captial Costs... Production Costs... HYDROGEN BY NONCATALYTIC PARTIAL OXIDATION OF HYDROCARBONS... Review of Processes... The Oxidation Reactor... Feed and Feed Preparation... Feed Ratios... V iii

3 CONTENTS 6 (continued) Pressure... Reactor Temperature... Reactor Space Velocities... Carbon Removal and Recovery. Process Description... Process Discussion... Capital Cost Estimates... Production Cost Estimates... HYDROGEN FROM CATALYTIC PARTIAL OXIDATION OF HYDROCARBONS...,., Review of Processes Feed Pressure Oxidation Catalyst The Partial Oxidation Reactors Process Description Process Discussion Capital Cost Estimates...,. Production Cost Estimates... 8 HYDROGEN FROM DECOMPOSITION OF HYDROCARBONS Review of Processes Hydrocarbon Feed Decomposition Catalyst.... Decomposition Conditions... Temperature Pressure Space Velocity Product Distribution.... Catalyst Regeneration.... Process Description Process Discussion Capital Cost Estimates..... Production Cost Estimates iv

4 CONTENTS 9 HYDROGEN PURIFICATION Catalytic Reaction processes.. Carbon Monoxide Shift Reaction Carbon Monoxide Methanation. Carbon Monoxide Oxidation.. Other Catalytic Reactions.. Absorption Processes Water Scrubbing Hot Carbonate Scrubbing... Ethanolamine Scrubbing.... Sulfinol Absorption..... Copper Liquor Scrubbing... Liquid Hydrocarbon Scrubbing. Liquid Nitrogen Scrubbing.. Other Absorption Processes.. Adsorption Processes Iow Temperature Processes... Diffusion Processes OTHER PROCESSES FOR HYDROGEN Small Hydrogen Plants Hydrogen from Coal The CO2 Accepter Process APPENDIXA DESIGN AND COST BASIS APPENDIX B DESIGN CURVES FOR TEXACO NONCATALYTIC PARTIAL OXIDATION PROCESS APPENDIX C PHYSICAL DATA APPENDIX D SAFETY AND MATERIALS OF CONSTRUCTION REFERENCES SUPPLEMENTARY REFERENCES

5 ILLUSTRATIONS How Hydrogen is used in the United States Hydrogen Consumption in Hydrotreating Refinery Streams.. 19 Effect of Temperature on the Reaction Equilibrium Constants in Steam-Methane-Reforming Reactions EFfect of Temperature on the Carbon Monoxide Shift Conversion Equilibrium Effect of Reformer Temperature and Steam-Methane Feed Ratio on Methane and Carbon Monoxide Conversion at 6 atm Pressure Effect of Pressure and Steam-Methane Ratio on Methane Conversion in Steam-Methane Reforming Rectangular Steam-Hydrocarbon Reforming Furnace Selas Corporation of America Design Terraced Wall Steam-Hydrocarbon Reforming Furnace Foster Wheeler Design Hydrogen by Catalytic Steam Reforming of Natural Gas Hydrogen by Catalytic Steam Reforming of Natural Gas Effect of Plant Capacity on Capital Investment Hydrogen by Catalytic Steam Reforming of Natural Gas Effect of Natural Gas Cost on Total Production Cost Hydrogen by Catalytic Steam Reforming of Natural Gas Effect of Plant Capacity and Production Rate on Total Production Cost Typical Cross Section and Temperature Profile for ICI Steam-Naphtha Reforming Furnace Effect of Reforming Pressure and Temperature on Naphtha- Steam Reforming Vii

6 ILLUSTRATIONS 5.11 Hydrogen by Catalytic Steam Reforming of Naphtha..., Hydrogen by Catalytic Steam Reforming of Naphtha Effect of Plant Capacity on Capital Cost Hydrogen by Catalytic Steam Reforming of Naphtha Effect of Naphtha Cost on Total Production Cost Hydrogen by Catalytic Steam Reforming of Naphtha Effect of Plant Capacity and Production Rate on Total Production Cost , Cross Section of Texaco Partial Oxidation Reactor Typical Shell and Texaco Partial Oxidation Reactor Burner Designs Hydrogen by Noncatalytic Partial Oxidation of Hydrocarbons Hydrogen by Noncatalytic Partial Oxidation of Hydrocarbons Effect of Plant Capacity on Capital Cost Hydrogen by Noncatalytic Partial Oxidation of Hydrocarbons Effect of Plant Capacity and Production Rate on Total Production Cost Hydrogen by Noncatalytic Partial Oxidation of Hydrocarbons Effect of Raw Material Cost on Total Production Cost Effect of Plant Capacity on Capital Investment Effect of Plant Capacity and Production Rate on Total Production Cost viii

7 ILLUSTRATIONS Effect of Raw Material Cost on Total Production Cost.... Effect of Decomposition Temperature on Methane Concentration in the Product Gas from the Catalytic Decomposition of Hydrocarbons... Relationship between Degree of Carbon Oxidation and Residual Carbon on Regenerated Catalyst from the Catalytic Hydrocarbon Decomposition Reactor , Effect of Plant Capacity and Reaction Pressure on Capital Cost Effect of Plant Capacity and Production Rate on Total Production Cost Effect of Natural Gas Cost on Total Production Cost.... Carbon Monoxide Shift Reaction Effect of Catalyst and Temperature on Reaction Rate.... Hot Carbonate Absorption Effect of Absorbent Flow Rate on Overall COa Transfer Coefficient , Hot Carbonate Absorption Effect of COa Partial Pressure on Overall COa Transfer Coefficient Zeolite A Adsorption Capacity Zeolite X Adsorption Capacity Comparison of Investment Costs for Heatless Adsorption, Palladium Diffusion, and Low Temperature (Cryogenic) Hydrogen Purification Processes ix

8 ILLUSTRATIONS B.l Effect of Sulfur in Feed on Hydrogen Generation.,,,,. 320 B.2 Effect of Oxygen-Oil Ratio on Soot Yield B.3 Comparison of Generator Performance with Naphtha and Heavy Oil Feed B.4 Carbon Conversion versus Oxygen-Carbon Ratio B.5 Effect of Pressure on Methane Content of Dry Synthesis Gas Made from Residual Fuel Oil with 2% Soot Yield B.6 Effect of Pressure on Methane Yield

9 TABLES Summary of Costs of Evaluated Hydrogen Processes..,... Summary of Technical Aspects of Evaluated Hydrogen Processes Hydrogen Plant Capacities Americas Hydrogen Plant Capacities Asia and Australasia Hydrogen Plant Capacities Europe, Africa, and the Middle East Hydrogen by Catalytic Steam Reforming of Light Hydrocarbons Summary of Processes Hydrogen by Catalytic Steam Reforming of Natural Gas Major Process Equipment and Utilities Summary Hydrogen by Catalytic Steam Reforming of Natural Gas StreamFlows Hydrogen by Catalytic Steam Reforming of Natural Gas Process Unit and Utilities Investment Hydrogen by Catalytic Steam Reforming of Natural Gas Total Capital Investment Hydrogen by Catalytic Steam Reforming of Natural Gas Production Costs Hydrogen by Catalytic Steam Reforming of Naphtha Summary of Processes Hydrogen by Catalytic Steam Reforming of Naphtha Major Process Equipment and Utilities Summary Hydrogen by Catalytic Steam Reforming of Naphtha StreamFlows... Hydrogen by Catalytic Steam Reforming of Naphtha Process Unit and Utilities Investment xi

10 TABLES Hydrogen by Catalytic Steam Reforming of Naphtha Total Capital Investment Hydrogen by Catalytic Steam Reforming of Naphtha Production Costs Summary of Processes Typical Performance Data of Shell and Texaco Processes Major Process Equipment and Utilities Summary StreamFlows Process Unit and Utilities Investment Total Capital Investment : Production Costs Hydrogen by Catalytic Partial Oxidation of Hydrocarbons Summary of Processes Major Process Equipment and Utilities Summary StreamFlows Process Unit and Utilities Investment Total Capital Investment Production Costs xii

11 TABLES Hydrogen by Catalytic Decomposition of Hydrocarbons Summary of Processes Major Process Equipment and Utilities Summary StreamFlows Process Unit and Utilities Investment Total Capital Investment Production Costs Comparison of Published and Derived Production Costs Important Impurities of Hydrogen in Specific Applications Comparison of Hydrogen Purification Processes......, 251 Carbon Monoxide Shift Reaction Summary of Processes Hydrogen Purification by Catalytic Carbon Monoxide Conversion Summary of Processes Hydrogen Purification by Absorption Summary of Processes Hydrogen Purification by Adsorption Summary of Processes Hydrogen Purification by Low Temperature Processes Summary of Processes xiii

12 TABLES 9.8 Hydrogen purification by Diffusion Processes Summary of Processes Comparison of Manufacturing Costs for Heatless Adsorption, Palladium Diffusion, and Low Temperature (Cryogenic) Hydrogen Purification Processes, Cost Comparison for Small Hydrogen Plants Based on Water Electrolysis, Ammonia Cracking, and Methanol Cracking Processes Hydrogen by Partial Oxidation of Solid Fuels Summary of Processes Hydrogen by Partial Oxidation of Coal Total Capital Investment Hydrogen by Partial Oxidation of Coal Production Costs C.l Hydrogen Physical Properties Summary of Data Sources xiv