Cost Effective Syngas Generation for Hydrogen Production
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1 I GSTC 2017 Syngas Technologies Conference, Colorado Springs Cost Effective Syngas Generation for Hydrogen Production Peter Neumann, PhD Caloric Anlagenbau GmbH, Lohenstr. 12, Gräfelfing, Germany 17 th October 2017 Caloric Anlagenbau GmbH 10/2017 Slide 1
2 I Company background Legal form GmbH (equals Ltd.) Foundation 1965 (roots going back to 1937) Ownership Head office Factory 100% private Gräfelfing near Munich, Germany Landsberg am Lech, Germany All engineering disciplines inhouse Shortest decision-making / response time Caloric Anlagenbau GmbH 10/2017 Slide 2
3 I Hydrogen generation plants I Syngas generation plants I Gas purification plants I Carbon monoxide generation plants I Gas sweetening Hydrogen HC plant 5000 Nm³/h, Malaysia I Incinerators / thermal oxidisers & acid recovery I Pilot / demonstration plants I Waste heat management systems & boilers I Engineering Total over 500 references Caloric Anlagenbau GmbH 10/2017 Slide 3
4 I Hydrogen generation plants H2 steam reformer (HC) single train: ~ 200 to Nm³/h twin train: to Nm³/h (~12 MMSCFD) H2 / syngas customized processes (HCX) capacities: ~ 100 to Nm³/h (~18 MMSCFD) 3D Nm³/h HCX syngas plant H2 methanol reformer (HM) capacities: ~ 200 to Nm³/h (~3.5 MMSCFD) Caloric Anlagenbau GmbH 10/2017 Slide Nm³/h HC hydrogen plant, The Netherlands
5 I Challenges for hydrogen production Syngas production for H 2 is mainly driven by: Evaluation / client focus: CAPEX / OPEX / TCO Site conditions: environmental requirements, availability and quality of utilities / feedstock Operating mode: 24h/7d, degree of automation, remote control, redundancy, 2oo3 voting systems Flexibility: turn down ratio, dual feedstock, H 2 -storage / consumer profile ( idling-mode ) Caloric Anlagenbau GmbH 10/2017 Slide 5
6 I CALORIC approach for cost effectiveness Profitability of plant design concept (optimisation of CAPEX/OPEX/Onstream-time) achieved by Fit for purpose Customized plant Skid mounted unit Modularisation Caloric Anlagenbau GmbH 10/2017 Slide 6
7 I CALORIC process units for hydrogen production Fuel Feed Feed pre-treatment (pre-) Reforming Shift (HT/LT) reaction Syngas cooling Hydrogen purification H 2 H 2 O BFW treatment Waste heat recovery Superheated steam Export steam Caloric Anlagenbau GmbH 10/2017 Slide 7
8 I CALORIC customisation EXAMPLE: Feed pre-treatment Criteria Solution(s) Natural gas: low S-content - single vessel high S-content (combined reaction) Odorisation - 2 vessel design LPG: Sulphur (splitted reaction) Olefins - 3 vessel design Refinery offgas: Sulphur (lead-lag system) Olefins Chlorides - splitted Hyd. vessels (intermediate cooling) Naphtha: Sulphur Olefins - additional layers/vessels Heavy metals (Cl, Pb removal) Caloric Anlagenbau GmbH 10/2017 Slide 8
9 I CALORIC modularisation Example: Typical number of skids: Typical number of modules: H 2 plant for 3000 Nm³/h (~ 2.7 MMSCFD) 10 (steel frames) 6 (reformer, PSA adsorbers, buffer tank) All interconnecting piping pre-manufactured Plug & play Caloric Anlagenbau GmbH 10/2017 Slide 9
10 I Caloric skid manufacturing Skid fabrication Caloric Anlagenbau GmbH 10/2017 Slide 10
11 I Caloric skid manufacturing Pre-erection of complete modularized skid-mounted plant Caloric Anlagenbau GmbH 10/2017 Slide 11
12 I Caloric pre-manufacturing Pre-fabricted interconnecting piping, preparation for packing Caloric Anlagenbau GmbH 10/2017 Slide 12
13 I Caloric modul shipping Packing of skid-modules into container for oveseas shipping Caloric Anlagenbau GmbH 10/2017 Slide 13
14 I Caloric on-site work Flue gas duct for waste heat management, 6.0 MW steam capacity, during erection Caloric Anlagenbau GmbH 10/2017 Slide 14
15 I Caloric on-site work PSA valve skid installation Process boiler installation Caloric Anlagenbau GmbH 10/2017 Slide 15
16 I CALORIC approach for cost effectiveness Cost Skid Mounted Unit (SMU) Stick Built Plant (SBP) Total Installed Cost (TIC) TIC SBP Cost savings TIC TIC SMU SMU SBP More profit Caloric Anlagenbau GmbH 10/2017 Slide 16 Equip. at site Commercial Production Time
17 I Engineered solution Location: Product: Capacity: Feed: Malaysia Hydrogen ( vol.-%) 5,000 Nm³/h (~ 4.5 MMSCFD) Natural gas Start: 2007 Hydrogen plant 5000 Nm³/h Schedule: 16 month from order until successful performance test Maximising of steam export results into cost reduction of supplementary equipment, making the project more profitable Caloric Anlagenbau GmbH 10/2017 Slide 17
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