H2A Case Study: Current Distributed Ethanol Reformer

Project Summary

Full Title:	H2A Case Study: Current (2005) Ethanol Steam Reformer (SR) at Forecourt 1500 kg/day
Project ID:	234
Principal Investigator:	Brian James
Keywords:	Hydrogen production; forecourt; ethanol; steam reforming

Purpose

The purpose of this analysis is to determine a baseline delivered cost of hydrogen for the forecourt production of hydrogen from ethanol steam reforming.

Performer

Principal Investigator:	Brian James
Organization:	Directed Technologies, Inc. (DTI)
Address:	3601 Wilson Blvd., Suite 650 Arlington, VA 22201
Telephone:	703-243-3383
Email:	Brian_James@DirectedTechnologies.com

Sponsor(s)

Name:	Fred Joseck
Organization:	DOE/EERE/HFCIT
Telephone:	202-586-7932
Email:	Fred.Joseck@ee.doe.gov

Period of Performance

Start:	February 2008
End:	May 2008

Project Description

Type of Project:	Analysis
Category:	Hydrogen Fuel Pathways

Methodology/Approach:	The delivered cost of hydrogen was determined using a discounted cash flow analysis on the total capital investment and the periodic expenditures for repair, maintenance, and replacement. Hysys simulation of the reformer system was conducted to confirm mass flows and electrical power requirements. Capital cost of the steam reformer system was estimated by a combination of scaling, industry quotes, and ground-up component cost estimation.

Methodology/Approach:

The delivered cost of hydrogen was determined using a discounted cash flow analysis on the total capital investment and the periodic expenditures for repair, maintenance, and replacement. Hysys simulation of the reformer system was conducted to confirm mass flows and electrical power requirements. Capital cost of the steam reformer system was estimated by a combination of scaling, industry quotes, and ground-up component cost estimation.

Models Used:	H2A Production model

Sensitivities Studied:	A tornado plot was developed to show the sensitivity of the delivered hydrogen cost to several important variables.

Timeframe Studied:	2005

Products/Deliverables

	Description: Spreadsheet Analysis Publication Title: Current (2005) Ethanol Steam Reformer (SR) at Forecourt 1500kg/day Publisher: National Renewable Energy Laboratory Author Name(s): Steward, Darlene http://www.hydrogen.energy.gov/h2a_prod_studies.html Publication Date: May 2008

Notes/Comments:	The ethanol reforming process is based on 20-atm conventional tube-in-shell Steam Reactor(SR) with PSA gas cleanup. Precious metal catalyst is assumed. The catalysted conversion of ethanol to methane is judged to occur rapidly to near full ethanol conversion in a compact adiabatic reformer. Since methane is the primary component of the pre-reformer, the remainder of the system is nearly identical to that of a natural gas reformer system. Ethanol is the sole feedstock and is also used as a supplemental fuel to the burner. A 950C burner adiabatic flame temperature and a 850C reformer temperature are assumed. Flue gas is exhaused at 110C. The PSA is based on 4 bed Batta cycle achieving 75% hydrogen recovery. The unit is assumed to be factory built (as opposed to on-site construction) and is skid-mounted for easy and rapid installation. A single 1500kg/day unit is assumed (as opposed to the previous H2A assumption of parallel 750kg/day units.) The system is assumed to be air cooled (and thus requires no cooling water flow). The product hydrogen exits the PSA at 300psi and is compressed for storage in metal cylinder storage tanks (2,500 psi max pressures). The hydrogen is next compressed to 6,250psi (max) for transfer into a 4 bed high pressure cascade system to allow rapid filling of 5,000 psi onboard H2 vehicular tanks.

Notes/Comments:

The ethanol reforming process is based on 20-atm conventional tube-in-shell Steam Reactor(SR) with PSA gas cleanup. Precious metal catalyst is assumed. The catalysted conversion of ethanol to methane is judged to occur rapidly to near full ethanol conversion in a compact adiabatic reformer. Since methane is the primary component of the pre-reformer, the remainder of the system is nearly identical to that of a natural gas reformer system. Ethanol is the sole feedstock and is also used as a supplemental fuel to the burner. A 950C burner adiabatic flame temperature and a 850C reformer temperature are assumed. Flue gas is exhaused at 110C. The PSA is based on 4 bed Batta cycle achieving 75% hydrogen recovery. The unit is assumed to be factory built (as opposed to on-site construction) and is skid-mounted for easy and rapid installation. A single 1500kg/day unit is assumed (as opposed to the previous H2A assumption of parallel 750kg/day units.) The system is assumed to be air cooled (and thus requires no cooling water flow). The product hydrogen exits the PSA at 300psi and is compressed for storage in metal cylinder storage tanks (2,500 psi max pressures). The hydrogen is next compressed to 6,250psi (max) for transfer into a 4 bed high pressure cascade system to allow rapid filling of 5,000 psi onboard H2 vehicular tanks.

Date Last Updated: 10/01/2008