1. H2P Energy
Large Scale Hydrogen
Production in Alberta
ENCH 531 WINTER 2014
LAWSON MACKENZIE, T’IEN MONTALVO, STEVEN RIETZE
1
2. Project Summary
•Goal: SMR plant capable of delivering 50,000 Nm3 of hydrogen per hour
•Inlet Feed Requirements:
• Natural Gas:
• 18,600 Nm3 per hour for reaction
• 10,400 Nm3 per hour for heating
• Water:
• 41,000 L per hour for reaction (consumed)
• 61,000 L per hour for cooling (recycled)
•Feed Costs:
• Water: $0.5/1000 gallons (minimal)
• Natural Gas: $4.51/GJ ($4.76/MMBtu, $4.76/MSCF)
• Annual Natural Gas Costs: $45.4 Million
• 64% for reformer feed
• 36% for combustion fuel
•Total Annual Operating Cost: $62.3 Million
• Natural Gas accounts for 73% of total
•Price of Hydrogen based on a DCFRR of 15%: $5.27/MSCF ($2.09/kg)
2
3. Alberta Water Use
3
Alberta Environment Information Centre. Water for life: current and future water use in Alberta. Alberta Environment: Edmonton, Alberta, 2007.1
4. Alberta Energy and Utilities Board. ST98-2013: Alberta’s Energy Reserves 2012 and Supply/Demand Outlook 2013-2022; ST98-2013; EUB: Calgary, AB, 20132
4
Conventional Crude Oil Supply and Demand
5. Alberta Energy and Utilities Board. ST98-2013: Alberta’s Energy Reserves 2012 and Supply/Demand Outlook 2013-2022; ST98-2013; EUB: Calgary, AB, 20132
5
Unconventional Crude Oil Supply and Demand
6. Crude Oil Export: Keystone Pipeline System
• Made up of several sections, most note worthy is
Keystone XL (currently unapproved for construction)
• Once complete Keystone XL will have capacity to flow
830,000 bbl/day of crude oil from Alberta to USA
• Combined Keystone exports from Alberta will then be
approximately 1,290,000 bbl/day, accounting for
52.2% of total crude oil production for 2012 (2,470,000
bbl/day)
• By 2022 total Alberta oil production expected to reach
4,270,000 bbl/day
• Combined Keystone exports would then account for
30.2% of provincial oil production
Image Source: TransCanada Corporation. Keystone XL Pipeline: About the Project.
http://keystone-xl.com/about/the-project (accessed Jan 26, 2014)3
6
7. Crude Oil Export: Railways
7
• Offer a cost competitive
alternative to pipeline transport
(although slightly more
expensive)
• Require minimal retro-fitting at
stations to accommodate
loading/unloading of crude oil
• Can also be used to access crude
oil markets not yet directly
available by pipeline
Image Source: Trains.
http://christophermartinphotography.com/cat
egory/trains (accessed Mar 26, 2014)4
8. Alberta Refinery Locations and Capacities
Alberta Energy and Utilities Board. ST98-2013: Alberta’s Energy Reserves 2012 and Supply/Demand Outlook 2013-2022; ST98-2013; EUB: Calgary, AB, 20132
8
9. Alberta Crude Oil Production, Upgrading, and Export
• If crude bitumen oversupply (approx. 210,000 bbl/day) upgraded/refined
in Alberta, the minimum amount of hydrogen required is 428,400 kg/day
(2.04 kg of hydrogen/bbl)6
• Given target hydrogen production for proposed plant is 100,000 kg/day,
amount of hydrogen required is more than 4 times greater
• Therefore, significant opportunity exists for creation of hydrogen
production facilities in Alberta
• Best location for hydrogen production plant is next to 1 of 3 refineries
immediately north of Edmonton
• Given current combined hydrogen requirement for Alberta (4 refineries
total) is approximately 929,220 kg/day
9
10. Project Economics
10
Plant Life [years] 30
Fixed Capital Investment 67,524,469$
Working Capital @ 7% of FCI 4,726,713$
Start-up Expenses @ 2% of FCI 1,350,489$
Total Capital Investment 73,601,671$
Salvage Value @ 10% of FCI 6,752,447$
Depreciation (straight line) [$/year] 2,025,734$
Tax Rate 25%
Operational Days per year 350
Total Expenses per year 62,264,149$
Hydrogen Production [kg/year] 3.65E+07
Hydrogen Production [Sm3/year] 4.10E+08
Hydrogen Production [1000SCF/year] 1.45E+07
Price of Hydrogen [$/kg] 2.09
Price of Hydrogen [$/1000SCF] 5.27
MARR 15.00%
Average ROI 14.91%
Total NPW 0$
DCFRR 15.00%
Payout Period [years] 6.15
16. Pressure Swing Adsorption (cont’d)
16
Linde AG. Hydrogen Recovery by Pressure Swing Adsorption. http://www.linde-engineering.com/internet.global.lindeengineering.global/en/images/HA_H_1_1_e_12_150dpi19_6130.pdf
(accessed September 30, 2013).8
.
17. 17
H2P Energy
Title
Project # Drawing #
Date
Scale
Drawer
Checker
Sheet
TM
LM, SR
24/3/2014
NONE ENCH 531 511-A 1 of 1
Natural Gas Pretreatment Units,
Syngas Phase Separators and
Heat Exchange Network
E-101
Heat Exchanger
2.7 MW
E-102 V-103R-101
Sulfur Scavenging
Reactor
84" I.D. x 30'-0" S/S
R-102
Sulfur Scavenging
Reactor
84" I.D. x 30'-0" S/S
C-101 E-103 E-104 V-102
R-101 R-102
FC
AC
SC
TC
LC
LC
TC
FC
PC
PC
AC AC
Treated
Water
Natural
Gas
To Process
Sewer
To Process
Sewer
Cooling
Water
511-C
511-B
511-B
511-B
Hot Syngas
from WGS
Reactor
Warm Treated
Water to BFW
Tank
Treated Natural
Gas to Reformer
Furnace Boiler Feed
Water
Boiler Feed
Water
To PSA
Units
Cooling
Water
Return
C-101
E-101
V-102
V-103
E-102 E-103
E-104
Heat Exchanger
7.9 MW
Heat Exchanger
6.5 MW
Heat Exchanger
1.9 MW
Water KO (2)
72" I.D. x 9'-11" T/T
Water KO (3)
72" I.D. x 7'-8" T/T
NG Compressor
12,000 CFM @ 2000
kPaa ΔP
1
23
4
5
18
19 20
21
22
23
24
PC
LC
To Process
Sewer
V-101
V-101
NG – Water KO
60" I.D. x 6'-11" T/T
18. 18
H2P Energy
Title
Project # Drawing #
Date
Scale
Drawer
Checker
Sheet
TM
LM, SR
24/3/2014
NONE ENCH 531 511-B 1 of 1
Steam-Methane
Reforming Furnace and
Water-Gas Shift Reactor
E-105
Heat Exchanger
17.1 MW
V-104
BFW Tank
1.6 m I.D. x 6.5 m T/T
R-103
Furnace & Steam-
Methane Reformer
11.3 MW
R-104
Water-Gas Shift
Reactor
1.5 m I.D. x 3.0 m T/T
F-101
Air Fan
73,000 CFM
@ 1.3 kPaa ΔP
F-102
Flue Gas Fan
91,000 CFM
@ 0.3 kPaa ΔP
ST-101
Flue Gas Stack
184" I.D. x 26'-0" T/T
TC
LC
FC
FC
SC
FC
TT
PT
AT
FCRC
PC
FT
PC FC
RC
FT
ATTT
511-A
511-A
511-A
Warm BFW
Fuel Gas
Hot Syngas
to Heat
Exchangers
Treated
Natural Gas
Export
Steam
Process
Steam
Reformer
Feed
Flue Gases
Air
P-101
BFW Pump
33.6 CMH @ 150
kPaa ΔP
P-102
BFW Pump
17.3 CMH @ 110
kPaa ΔP
E-105
F-101
F-102
P-101
P-102
R-103
R-104
ST-101
V-104
Reformer
Syngas
Effluent
4
5
6
7
8
9
10
11
12
13
14
TTTT
15
16
18
511-C
PSA Tail Gas
19. 19
511-A
H2P Energy
Title
Project # Drawing #
Date
Scale
Drawer
Checker
Sheet
TM
LM, SR
24/3/2014
NONE ENCH 531 511-C 1 of 1
Pressure Swing
Adsorption Unit
Cooled
Syngas
from Heat
Exchangers
PSA Tail Gas
V-105 V-106 V-107 V-108
V-105
PSA
Vessel (1)
3.5 m I.D. x 10.6 m T/T
V-106
PSA
Vessel (2)
3.5 m I.D. x 10.6 m T/T
V-107
PSA
Vessel (3)
3.5 m I.D. x 10.6 m T/T
V-108
PSA
Vessel (4)
3.5 m I.D. x 10.6 m T/T
Hydrogen
V-109
PSA Tail Gas Buffer Tank
72" I.D. x 7'-8" T/T
V-109
LC
PC
PC FT
To Process
Sewer
TT
PT
AT
TT
PT
AT
TT
PT
AT
TT
PT
AT
24
25
26
27
511-B
23. Dry Reforming of Methane: An Assessment
23
CO2 + CH4 ↔ 2H2 + 2CO ΔH°rxn = 247 kJ/mol
Feed
Pretreatment
Reforming
Water-Gas
Shift
Pressure Swing
Adsorption
Waste Heat
Recovery
Water
Natural
Gas
Steam
PSA Tail
Gas
Export Steam
Hydrogen
Carbon
Dioxide
Flue Gases
19,000
Sm3/h
Steam
50,000
Nm3/h
Hydrogen Purge
Gas
9,000
kg CO2/h
16,000
kg CO2/h
22,000
kg CO2/h
TOTALS
SMR: 22,000 + 9,000 = 31,000 kg CO2/h
DMR: 16,000 kg CO2/h
40,000
L/h
24. Reverse Water-Gas Shift Reaction (RWGS)
24
H2 + CO2 ↔ H2O+ CO ΔH°rxn = 40 kJ/mol
Oyama ST, Hacarlioglu P, Gu Y, Lee D. Dry reforming of methane has no future for hydrogen production: Comparison with steam reforming at high pressure in standard and
membrane reactors. International Journal of Hydrogen Energy, 2012; 37:10444-10450.9
25. Catalyst Deactivation Due to Coking
25
CH4 ↔ 2H2+ C ΔH°rxn = 75 kJ/mol
2CO ↔ CO2+ C ΔH°rxn = -172 kJ/mol
Kahle L.C.S., Roussiere T., Maier L., Herrera Delgado K., Wasserschaff G., Schunk S.A., and Deutschmann O. Methane Dry Reforming at Higt Temperatures and Elevated
Pressure: Impact of Gas-Phase Reactions. I&EC research: Industrial & Engineering Chemistry Research. 2013: 52(34), 11920-11930. 10
26. Products Derived from Syngas
26
Ricci M, Perego C. From syngas to fuels and chemicals: chemical and biotechnological routes.
http://www.eurobioref.org/Summer_School/Lectures_Slides/day6/L17_M.Ricci.pdf (accessed December 3, 2013).11
27. Conclusion
27
• Steam methane reforming is a reliable and time-tested technology to produce
hydrogen
• Given current economic conditions in the province, it is recommended that at
least one but not more than four SMR plants capable of producing 50,000
Nm3 of hydrogen per hour be constructed
• Based on a DCFRR of 15% and an average natural gas price of $4.51 per GJ,
the recommended sales price of hydrogen is $5.27 per MSCF ($2.09 per kg)
• Due to current technical limitations and a lack of reduction in net carbon
emissions, dry reforming of methane is not economically or environmentally
feasible at this time
28. References
1. Alberta Environment Information Centre. Water for life: current and future water use in Alberta. Alberta Environment:
Edmonton, Alberta, 2007.
2. Alberta Energy and Utilities Board. ST98-2013: Alberta’s Energy Reserves 2012 and Supply/Demand Outlook 2013-2022;
ST98-2013; EUB: Calgary, AB, 2013
3. TransCanada Corporation. Keystone XL Pipeline: About the Project. http://keystone-xl.com/about/the-project (accessed Jan
26, 2014)
4. Trains. http://christophermartinphotography.com/category/trains (accessed Mar 26, 2014)
5. M-I SWACO. H2S Removal through Fixed Bed Technologies. 9th Biogas Conference, Montreal, QC, May 25, 2011.
6. Thysen Krupp Uhde GmbH. The proprietary Uhde top-fired steam reformer. https://procurement.uhde-
web.de/competence/technologies/ammonia/techprofile.en.epl?profile=1&pagetype=1&pagenum=1 (accessed March 6th ,
2014)
7. Caloric Anlagenbau GmbH. Pressure Swing Adsorption.
http://www.caloric.com/upload/Products/H2Generation/HC_1000.jpg (accessed April 28th, 2014).
8. Linde AG. Hydrogen Recovery by Pressure Swing Adsorption. http://www.linde-
engineering.com/internet.global.lindeengineering.global/en/images/HA_H_1_1_e_12_150dpi19_6130.pdf (accessed
September 30, 2013).
9. Oyama ST, Hacarlioglu P, Gu Y, Lee D. Dry reforming of methane has no future for hydrogen production: Comparison with
steam reforming at high pressure in standard and membrane reactors. International Journal of Hydrogen Energy, 2012;
37:10444-10450.
10. Kahle L.C.S., Roussiere T., Maier L., Herrera Delgado K., Wasserschaff G., Schunk S.A., and Deutschmann O. Methane Dry
Reforming at Higt Temperatures and Elevated Pressure: Impact of Gas-Phase Reactions. I&EC research: Industrial &
Engineering Chemistry Research. 2013: 52(34), 11920-11930.
11. Ricci M, Perego C. From syngas to fuels and chemicals: chemical and biotechnological routes.
http://www.eurobioref.org/Summer_School/Lectures_Slides/day6/L17_M.Ricci.pdf (accessed December 3, 2013).
28
31. 31
H 2P En er g y DWG NO:
800-MAST-A01
A2
A2
PDT
803
PDI
803
PDT
812
PDI
812
L.O.
L.O.
AT
804
AT
808
A2
L.O.
L.O.
A2
PDT
807
PDI
807
LT
812D/P
LIC
812
LAH
812
LAL
812
LV
812
LY
812
P
I
LSLL
812
LALL
812
LSHH
812
LAHH
812
LG
812
A2
A02C2
PV
812
PT
812
PI
812
PAH
812
PAL
812
PI
812
L.O.
L.O.
A2
A02 C2
PIC
812
PY
812
P
I
PV
800
PT
800
PI
800
PAH
800
PAL
800
PI
800
PIC
800
P
I
PY
800
AT
801
AIC
801
FY
801
FIC
801
FY
801
P
I
FV
801
PLC
FY
810
FY
811
FY
809
FY
806
FY
802
805
FY
F.C.
F.C.
F.O.
F.O.
PSV
814
PSV
813
PSV
815
SKID #1
SKID #2
1/4"WT-004-N-A2
R-8800 R-8801
V-8800
LLLL 14"
LLL 15"
NLL 15.5"
HLL 15.7"
HHLL 18"
1'00"
PROCESS
WATER
NATURAL
GAS
TO PROCESS
SEWER
TO WARM
FLARE
TO C-8800A/B
TO WARM
FLARE
TO WARM
FLARE
FROM C-8800A/B
NG COMPRESSOR
R-8800
NG PRETREATER
84" I.D. x 30'-0" S/S
29 PSIA @ 77°F
60,000 LBS
SULFATREAT LOADING
R-8801
NG PRETREATER
84" I.D. x 30'-0" S/S
29 PSIA @ 77°F
60,000 LBS
SULFATREAT LOADING
V-8800
NG PHASE SEPARATOR
60" I.D. x 6'-11" T/T
29 PSIA @ 25°C
NG COMPRESSOR
20"
MW
20"
MW
20"
MW
20"
MW
12"HG-001-N-A2
12"HG-002-N-A2
1/4"WT-005-N-A2
12"HG-007-N-A2
12"HG-008-N-A2
12"HG-009-N-A2
12"HG-010-N-A2
12"HG-011-N-A2
12"HG-012-N-A2
14"HG-013-1"HC-C2
1/4"DY-014-N-A2 1/4"DY-015-N-A2
14"HG-017-1"HC-C2
ALBERTA PROCESS
DEVELOPMENT
CORPORATION
PLOT SCALE:
1=1
SCALE:
NONE
AFE: LOCATION:
REV:
A
DATE:
APRIL 14, 2014
STEAM-METHANE REFORMER PIPING AND
INSTRUMENTATION DIAGRAM
NG PRETREATERS AND PHASE
SEPARATOR #1
REVISIONS:
LINE DESIGNATION
AA”BB-CCC-D-E-FFF
AA: NOMINAL SIZE LINE
BB: SERVICE CODE
CCC: LINE NUMBER
D: INSULATON SIZE
E: INSULATION CLASS
FFF: PIPING SPECIFICATION
INSULATION
CLASS TYPE
C: CONSENSATE CONTROL
HC: HOT INSULATION
(CALCIUM SILICATE
N: NONE
LINE COMMODITIES
CODE SERVICE
DY: SANITARY SEWER
EX: EXHAUST
FG: FUEL GAS
HG: HYDROCARBON GAS
WT: PROCESS WATER
CW: COOLING WATER
PIPING SPECIFICATIONS
A2
A: NOMINAL PRESSURE CLASS
2: PIPING MATERIAL
NOMINAL PRESSURE
CLASS
A: 150 PSI
B: 300 PSI
C: 400 PSI
D: 600 PSI
PIPING MATERIAL
1: CAST IRON
2: CARBON STEEL
3: 304 OR 304L S.S.
32. 32
H 2P En er g y DWG NO:
800-MAST-A02
AFE:
A01C2
M
FE
816
FT
816
FI
816
FAL
816
FAH
816
F.O.
A01 C2
ASV
816
ASY
816
PT
816
PI
816
PAH
816
PAL
816 PIC
816
SY
816
ASC
816
ASY
816
FI
816
FIC
816
ASY
817
818
PT
PI
818
PIC
818
ASY
819
PI
818
PAH
818
PAL
818
P
I
PI
816
M
FE
820
FT
820
FI
820
FAL
820
FAH
820
F.O.
ASV
819
ASY
819
PT
819
PI
819
PAH
819
PAL
819 PIC
819
SY
819
ASC
819
ASY
819
FI
820
FIC
820
ASY
820
821
PT
PI
821
PIC
821
ASY
821
PI
821
PAH
821
PAL
821
P
I
PI
819
L.O.
L.O.
A06B13
A05 C13
F.C.
TV
825
TY
825
P
I
TE
824
TI
824
N.C.
A2
RTD
TE
822
TI
822
RTD
TIC
823
TE
823
RTD
TT
823
TAH
823
TAL
823
A2
D2
TE
826
TI
826
RTD
L.O.
L.O.
TE
827
TI
827
N.C.
RTD
TE
829
TI
829
RTD
N.C.
TE
828
TI
828
RTD
TE
830
RTD
TT
830
L.O.
L.O.
TE
831
TI
831
N.C.
RTD
TE
833
TI
833
RTD
N.C.
TE
832
TI
832
RTD
TE
834
RTD
TT
834
A04D2
A03B13
C-8800A C-8800B
E-8800 E-8801
E-8802
A2
SKID #2
SKID #3
SKID #4
PSV
837
PSV
836
PSV
835DRY NATURAL
GAS
FROM
V-8800
NATURAL GAS
RECYCLE
TO V-8800
TO R-8802
REFORMER
FURNACE
FROM R-8803
WGS REACTOR
EFLLUENT
TO WARM
FLARE
TO WARM
FLARE
TO WARM
FLARE
BOILER FEED
WATER
BOILER FEED
WATER TANK
TO V-8801
TO E-8803
R-8800A/B
NG COMPRESSOR(S)
16 STAGES
12,000 CFM @ 2000 kPaa ΔP
E-8800
NG PREHEATER
2.7 MW
SHELL: 2200 kPaa @ 25/310°C
TUBES: 1870 kPaa @ 350/420°C
2 TUBE PASSES/2 CROSS PASSES
E-8801
SYNGAS COOLER #1
4.0 MW
SHELL: 3100 kPaa @ 25/180°C
TUBES: 1770 kPaa @ 140/350°C
2 TUBE PASSES/18 CROSS PASSES
E-8802
SYNGAS COOLER #2
4.0 MW
SHELL: 3100 kPaa @ 25/180°C
TUBES: 1770 kPaa @ 140/350°C
2 TUBE PASSES/18 CROSS PASSES
14"HG-017-1"HC-C2
14"HG-018-1"HC-C2
6"HG-019-1"HC-C2
6"HG-020-1"HC-C2
6"HG-025-1"HC-C2
8"HG-027-1 1/2"HC-C13
14"HG-033-2"HC-B13
14"HG-035-1 1/2"HC-B13
14"HG-036-1 1/2"HC-B13
10"HG-038-1 1/2"C-B13
3"WT-067-N-D2
3"WT-069-1"HC-D2
10"WT-071-1"HC-D2
H 2P En er g y DWG NO:
ALBERTA PROCESS
DEVELOPMENT
CORPORATION
1=1
SCALE:
NONE
LOCATION:
REV:
A
DATE:
APRIL 14, 2014
STEAM-METHANE REFORMER PIPING AND
INSTRUMENTATION DIAGRAM
NG COMPRESSOR(S) AND HEAT
EXCHANGER(S) #1 & #2
REVISIONS: PLOT SCALE:
33. 33
H 2P En er g y DWG NO:
800-MAST-A03
AFE:
L.O.
L.O.
TE
838
TI
838
RTD
TE
840
TI
840
RTD
N.C.
E-8803
A02B13
D2
TE
839
TI
839
RTD
N.C.
TE
841
TI
841
RTD
A2
L.O.
L.O.
TE
842
TI
842
RTD
TE
844
TI
844
RTD
N.C.
E-8804
TE
843
TI
843
RTD
N.C.
TE
845
TI
845
RTD
L.O.
L.O.
TE
846
TI
846
RTD
TE
848
TI
848
RTD
N.C.
E-8805
TE
847
TI
847
RTD
N.C.
TE
849
TI
849
RTD
A2
A2
L.O.
L.O.
TE
850
TI
850
RTD
TE
852
TI
852
RTD
N.C.
E-8806
TE
851
TI
851
RTD
N.C.
TE
853
TI
853
RTD
A04D2
A2
SKID #5
A07B2
PSV
855
PSV
857
PSV
856
PSV
854
FROM E-8802
BOILER FEED
WATER
TO WARM
FLARE
TO WARM
FLARE
TO WARM
FLARE
TO WARM
FLARE
BOILER FEED
WATER TANK
TO V-8801
E-8803
SYNGAS COOLER #3
1.6 MW
SHELL: 3100 kPaa @ 25/110°C
TUBES: 1470 kPaa @ 120/70°C
2 TUBE PASSES/13 CROSS PASSES
E-8804
SYNGAS COOLER #4
1.6 MW
SHELL: 3100 kPaa @ 25/110°C
TUBES: 1470 kPaa @ 120/70°C
2 TUBE PASSES/13 CROSS PASSES
E-8805
SYNGAS COOLER #5
1.6 MW
SHELL: 3100 kPaa @ 25/110°C
TUBES: 1470 kPaa @ 120/70°C
2 TUBE PASSES/13 CROSS PASSES
E-8806
SYNGAS COOLER #6
1.6 MW
SHELL: 3100 kPaa @ 25/110°C
TUBES: 1470 kPaa @ 120/70°C
2 TUBE PASSES/13 CROSS PASSES
TO V-8802 PHASE
SEPARATOR
10"HG-038-1 1/2"C-B13
10"HG-040-11/2"C-B13
10"HG-042-1 1/2"C-B13
10"HG-044-11/2"C-B13
10"HG-046-1"C-B2
4"WT-072-N-D2
4"WT-074-1"HC-D2
4"WT-076-1"HC-D2
4"WT-078-1"HC-D2
4"WT-080-1"HC-D2
H 2P En er g y DWG NO:
ALBERTA PROCESS
DEVELOPMENT
CORPORATION
1=1
SCALE:
NONE
LOCATION:
REV:
A
DATE:
APRIL 14, 2014
STEAM-METHANE REFORMER PIPING AND
INSTRUMENTATION DIAGRAM
HEAT EXCHANGER(S) #3
REVISIONS: PLOT SCALE:
34. 34
H 2P En er g y DWG NO:
800-MAST-A04
AFE:
HHLL 1.2 m
HLL 1.0 m
NLL 0.8 m
LLL 0.5 m
LLLL 0.2m
LT
858 D/P
LIC
858
LAH
858
LAL
858
P
I
LSLL
858
LALL
858
LSHH
858
LAHH
858
LG
858
F.C.
A03D2 A02 D2
LV
858
LY
858
AT
858
AI
858
AAH
858
FE
858
FT
858
FI
858
FI
858
V-8801
A06 D2
A05D2
L.O.
L.O.
PT
858
F.O.
PV
858
PY
858
PIC
858
PI
858
PAL
858
PAH
858
PI
858
A2
F.O.
859
PT
M
860
PT
F.O.
A06D2
PI
859
PI
859FE
860
PI
860
PI
860
FT
860
FY
860
P
I
P
I
FIC
860
FI
860
FV
860
FV
861
FY
861
P
I
F.O.
862
PT
M
863
PT
F.O.
PI
862
PI
862FE
863
PI
863
PI
863
FT
863
FY
863
P
I
FIC
863
FI
863
FV
863
FV
864
FY
864
P
I
F.O.
865
PT
M
866
PT
F.O.
PI
865
PI
865 FE
866
PI
866
PI
866
FT
866
FY
866
P
I
FIC
866
FI
866
FV
866
FV
867
FY
867
P
I
F.O.
868
PT
M
869
PT
F.O.
PI
868
PI
868 FE
869
PI
869
PI
869
FT
869
FY
869
P
I
FIC
869
FI
869
FV
869
FV
870
FY
870
P
I
A05 D2
A05D2
20m
GRADE
PSV
871
P-8800AP-8800B
P-8801A P-8801B
SKID #6
FROM E-8806
SHELL
FROM E-8802
SHELL
FROM E-8807
REFORMER
FURNACE
TO R-8802
REBOILER
TO WARM
FLARE
FROM R-8802
REFORMER
FURNACE
20"
MW
TO E-8807 REBOILER TO R-8802 REFORMER
FURNACE
V-8801
BFW TANK
1.6 m I.D. x 6.5 m T/T
2800 kPaa @ 200°C
P-8800A/B
BFW PUMP(S)#1
33.6 CMH @ 150 kPaa ΔP
HP: 3.0
P-8801A/B
BFW PUMP(S)#2
17.3 CMH @ 110 kPaa ΔP
HP: 1.0
10"WT-071-1"HC-D24"WT-080-1"HC-D2
6"WT-083-1"HC-D2
3"WT-084-1"HC-D2
3"WT-084-1"HC-D2
3"WT-084-1"HC-D2
2 1/2"WT-085-1"HC-D2
21/2"WT-085-1"HC-D2
6"WT-088-2"HC-D2
2"WT-089-1"HC-D2
2"WT-089-1"HC-D2
2"WT-089-1"HC-D2
1 1/2"WT-090-1"HC-D2
11/2"WT-090-1"HC-D2
3"WT-093-1"HC-D2 3"WT-094-1"HC-D2
2"WT-092-2"HC-D2
H 2P En er g y DWG NO:
ALBERTA PROCESS
DEVELOPMENT
CORPORATION
1=1
SCALE:
NONE
LOCATION:
REV:
A
DATE:
APRIL 14, 2014
STEAM-METHANE REFORMER PIPING AND
INSTRUMENTATION DIAGRAM
BFW TANK AND PUMPS
REVISIONS: PLOT SCALE:
35. 35
H 2P En er g y DWG NO:
AFE:
A2
M
FE
872
FT
872
FI
872
PT
872
PI
872
SY
872
873
PT PI
873
M
FE
874
FT
874
FI
874
PT
874
PI
874
SY
874
875
PT PI
875
M
FE
887
FT
887
FI
887
PT
887
PI
887
SY
887
888
PTPI
888
M
FE
889
FT
889
FI
889
PT
889
PI
889
SY
889
890
PTPI
890
AT
891
AI
891
TE
891
TI
891
RTD
A2
F.C.
F.O. F.O.
A2
A09 B2
TE
882
TI
882
RTD
TE
883
TI
883
RTD
TE
885
TI
885
RTD
PT
884
PI
884
A02 C13
A06B13
AT
XXX
AI
XXX
TE
XXX
TI
XXX
RTD
A04D2
A04D2
A04D2
AT
881
AI
881
TE
881
TI
881
RTD
AT
877
PLC
FE
878
FT
878
FV
880
PV
879
PY
879
FY
880
PLC
886
PT
FE
877
FE
876
FV
876
FY
876
AT
876
FT
876
FT
877
F-8800A F-8800B
F-8801A
F-8801B
P
I
P
I
P
I
R-8802
SKID #7
FLUE
GASES
TO
ATMOSPHERE
COMBUSTION
AIR
EXPORT
STEAM
NATURAL GAS
FROM E-8800
SHELL
TO E-8807
TUBES
SYNGAS
PSA TAIL GAS
FROM V-8805
FUEL GAS
FROM P-8801
BFW PUMP
TO V-8801
BFW TANK
FROM V-8801
BFW TANK
F-8800A/B
FORCED DRAFT FAN(S)
73,000 CFM
1.5 kPaa ΔP
F-8801A/B
INDUCED DRAFT FAN(S)
91,000 CFM
0.5 kPaa ΔP
R-8802
REFORMER FURNACE
17 x 11 x 16 m BOX @ 11.3 MW
2200 kPaa @ 1200°C
114.3 mm I.D. x 13 m PER TUBE
# OF TUBES = 136
ST-8800
FLUE GAS STACK
184" I.D. x 26'-0" T/T
14.7 PSIA @ 150°C
8"HG-027-1 1/2"HC-C13
10"HG-028-2"HC-C13
12"HG-029-2"HC-C13
16"HG-030-3"HC-B13
A2
11/2"WT-090-1"HC-D2
2"WT-092-2"HC-D2
3"WT-094-1"HC-D2
8"WT-098-2 1/2"HC-D2 8"WT-101-2 1/2"HC-D2
12"HG-066-1/2"C-B2
10"FG-102-N-A2
H 2P En er g y DWG NO:
800-MAST-A05
AFE:
H 2P En er g y DWG NO:
ALBERTA PROCESS
DEVELOPMENT
CORPORATION
1=1
SCALE:
NONE
LOCATION:
REV:
A
DATE:
APRIL 14, 2014
STEAM-METHANE REFORMER PIPING AND
INSTRUMENTATION DIAGRAM
REFORMER FURNACE, FORCED &
INDUCED DRAFT FANS AND STACK
REVISIONS: PLOT SCALE:
36. 36
H 2P En er g y DWG NO:
800-MAST-A06
AFE:
PDT
898
PDI
898
R-8803
E-8804
E-8807
A05B13
A04D2
A04 D2
TE
892
TI
892
RTD
TE
894
TIC
894
RTD
TE
896
TI
896
RTD
N.C.
TE
895
TI
895
RTD
TV
893
TY
893
P
I
TT
894
TAH
894
TAL
894
L.O.
L.O.
PSV
900
F.C.
TE
897
TI
897
RTD
AT
897
AI
897
TE
899
TI
899
AT
899
AI
899
A02B13
L.O.
L.O.
PSV
901
A2
SKID #7
SKID #8
20"
MW
TO WARM
FLARE
TO WARM
FLARE
TO V-8801
BFW TANK
FROM P-8800
BFW PUMP
FROM R-8802
REFORMER
FURNACE
TO E-8800
E-8807
REBOILER
17.1 MW
SHELL: 3000 kPaa @ 180/240°C
TUBES: 1990 kPaa @ 420/850°C
2 TUBE PASSES
R-8803
WGS REACTOR
1.5 m I.D. x 3.0 m T/T
1750 kPaa @ 430°C
2,800 kg
CATALYST LOADING
16"HG-030-3"HC-B13
14"HG-032-2"HC-B13
14"HG-033-2"HC-B13
A2
2 1/2"WT-085-1"HC-D2
6"WT-088-2"HC-D2
H 2P En er g y DWG NO:
ALBERTA PROCESS
DEVELOPMENT
CORPORATION
1=1
SCALE:
NONE
LOCATION:
REV:
A
DATE:
APRIL 14, 2014
STEAM-METHANE REFORMER PIPING AND
INSTRUMENTATION DIAGRAM
BFW KETTLE REBOILER AND WGS
REACTOR
REVISIONS: PLOT SCALE:
37. 37
H 2P En er g y DWG NO:
800-MAST-A07
AFE:
PDT
902
PDI
902 XXX
XXX
LT
902D/P
LIC
902
LAH
902
LAL
902
LV
902
LY
902
P
I
LSLL
902
LALL
902
LSHH
902
LAHH
902
LG
902
PV
902
PT
902
PI
902
PAH
902
PAL
902
PI
902
L.O.
L.O.
A2
PIC
902
PY
902
P
I
F.O.
F.O.
PSV
907
V-8802
LLLL 14"
LLL 15"
NLL 15.1"
HLL 15.2"
HHLL 16"
1'00"
A03B2
A2
L.O.
L.O.
TE
903
TI
903
RTD
TE
905
TI
905
RTD
N.C.
E-8808
TE
904
TI
904
RTD
N.C.
TE
906
TI
906
RTD
A2
PSV
908
A08D2
A08B2
TV
905
D2
TY
905
P
I
TIC
905
TAH
905
TAL
905
A08
SKID #9 SKID #10
FROM E-8806
COOLED
SYNGAS
TO WARM
FLARE
TO PROCESS
SEWER
20"
MW
TO WARM
FLARE
COOLING
WATER
TO E-8809
TUBES
TO E-8809
SHELL
V-8802
PHASE SEPARATOR
72" I.D. x 9'-11" T/T
184 PSIA @ 70°C
E-8808
SYNGAS COOLER #7
0.6 MW
SHELL: 101 kPaa @ 25/50°C
TUBES: 1270 kPaa @ 30/70°C
2 TUBE PASSES/27 CROSS PASSES
TO TT 914
10"HG-046-1"C-B2
2"DY-047-N-A2 2"DY-048-N-A2
10"HG-050-1"C-B2 10"HG-051-1"C-B2
10"HG-054-1"C-B2
4"CW-103-N-D2
4"CW-104-N-D2
H 2P En er g y DWG NO:
ALBERTA PROCESS
DEVELOPMENT
CORPORATION
1=1
SCALE:
NONE
LOCATION:
REV:
A
DATE:
APRIL 14, 2014
STEAM-METHANE REFORMER PIPING AND
INSTRUMENTATION DIAGRAM
PHASE SEPARATOR #2 AND HEAT
EXCHANGER #4
REVISIONS: PLOT SCALE:
38. 38
H 2P En er g y DWG NO:
800-MAST-A08
AFE:
L.O.
L.O.
TE
909
TI
909
RTD
TE
911
TI
911
RTD
N.C.
E-8809
TE
910
TI
910
RTD
N.C.
TE
912
TI
912
RTD
L.O.
L.O.
TE
913
TI
913
RTD
TE
915
TI
915
RTD
N.C.
E-8810
TE
914
TT
914
RTD
N.C.
TE
916
TI
916
RTD
PSV
919
PSV
918
PDT
917
PDI
917 XXX
XXX
LT
917D/P
LIC
917
LAH
917
LAL
917
LV
917
LY
917
P
I
LSLL
917
LALL
917
LSHH
917
LAHH
917
LG
917
A2
A09B2
PV
917
PT
917
PI
917
PAH
917
PAL
917
PI
917
L.O.
L.O.
A2
PIC
917
PY
917
P
I
F.O.
F.O.
PSV
920
V-8803
LLLL 14"
LLL 15"
NLL 16.7"
HLL 17.4"
HHLL 20"
1'00"
A07D2
A07B2
D2
A2
A2
SKID #10
SKID #11
FROM E-8808
TUBES
FROM E-8808
SHELL
A07
TO TIC
905
TO COOLING
WATER RETURN
TO WARM
FLARE
TO WARM
FLARE
TO WARM
FLARE
TO V-8804
A/B/C/D
PSA UNIT
TO PROCESS
SEWER
E-8809
SYNGAS COOLER #7
0.6 MW
SHELL: 101 kPaa @ 25/50°C
TUBES: 1270 kPaa @ 30/70°C
2 TUBE PASSES/27 CROSS PASSES
E-8810
SYNGAS COOLER #7
0.6 MW
SHELL: 101 kPaa @ 25/50°C
TUBES: 1270 kPaa @ 30/70°C
2 TUBE PASSES/27 CROSS PASSES
V-8803
PHASE SEPARATOR
72" I.D. x 7'-8" T/T
155 PSIA @ 30°C
10"HG-054-1"C-B210"HG-056-1"C-B2
10"HG-058-1/2"C-B2
1/2"DY-059-N-A2
1/2"DY-060-N-A2
10"HG-062-1/2"C-B2 10"HG-063-1/2"C-B2
4"CW-104-N-D2
4"CW-105-N-D2
4"CW-106-N-D2
H 2P En er g y DWG NO:
ALBERTA PROCESS
DEVELOPMENT
CORPORATION
1=1
SCALE:
NONE
LOCATION:
REV:
A
DATE:
APRIL 14, 2014
STEAM-METHANE REFORMER PIPING AND
INSTRUMENTATION DIAGRAM
HEAT EXCHANGER(S) #4 AND PHASE
SEPARATOR #3
REVISIONS: PLOT SCALE:
39. 39
H 2P En er g y DWG NO:
800-MAST-A09
AFE:
PDT PDI
XXX
XXX
LT
934D/P
LIC
934
LAH
934
LAL
934
LV
934
LY
934
P
I
LSLL
934
LALL
934
LSHH
934
LAHH
934
LG
934
A2
PV
934
PT
934
PI
934
PAH
934
PAL
934
PI
934
L.O.
L.O.
A2
PIC
934
PY
934
P
I
F.O.
F.O.
PSV
XXX
V-8805
LLLL 14"
LLL 15"
NLL 15.5"
HLL 16"
HHLL 16.5"
1'00"
A08B2
A05 B2
R-8804A
PDT
922
PDI
922
R-8804B
PDT
925
PDI
925
R-8804C
PDT
928
PDI
928
R-8804D
PDT
931
PDI
931
AI
922
RTD
TE
922
AT
922
AI
925
RTD
TE
925
AT
925
AI
928
RTD
TE
928
AT
928
AI
XXXX
RTD
TE
931
AT
931
TE
921
RTD
AI
921
AT
921
AI
921
TE
924
RTD AI
924
AT
924
AI
924
TE
927
RTD AI
927
AT
927
AI
927
AT
930
AI
930
TE
930
RTD AI
930
A2
TI
922
TAH
922
TAL
922
TI
925
TAH
925
TAL
925
TI
928
TAH
928
TAL
928
TI
931
TAH
931
TAL
931
RTD
TE
923
TI
923
AT
923
AI
923
RTD
TE
926
TI
926
AT
926
AI
926
RTD
TE
929
TI
929
AT
929
AI
929
RTD
TE
932
TI
932
AT
932
AI
932
FROM V-8803
COOLED
SYNGAS
TO R-8802
REFORMER
FURNACE
HYDROGEN
PRODUCT
TO PROCESS
SEWER
TO WARM
FLARE
V-8805
PHASE SEPARATOR
72" I.D. x 7'-8" T/T
155 PSIG @ 30°C
V-8804A
PSA VESSEL
3.5 m I.D. x 10.6 m T/T
1100 kPaa @ 30°C
50,000 kg
ADSORBENT LOADING
V-8804B
PSA VESSEL
3.5 m I.D. x 10.6 m T/T
1100 kPaa @ 30°C
50,000 kg
ADSORBENT LOADING
V-8804C
PSA VESSEL
3.5 m I.D. x 10.6 m T/T
1100 kPaa @ 30°C
50,000 kg
ADSORBENT LOADING
V-8804D
PSA VESSEL
3.5 m I.D. x 10.6 m T/T
1100 kPaa @ 30°C
50,000 kg
ADSORBENT LOADING
PLC10"HG-063-1/2"C-B2
10"EX-065-1/2"C-A2
12"HG-066-1/2"C-B2
FE
933
FT
933
FI
933
934934
H 2P En er g y DWG NO:
ALBERTA PROCESS
DEVELOPMENT
CORPORATION
1=1
SCALE:
NONE
LOCATION:
REV:
A
DATE:
APRIL 14, 2014
STEAM-METHANE REFORMER PIPING AND
INSTRUMENTATION DIAGRAM
PSA VESSELS AND PSA TAIL GAS BUFFER
TANK
REVISIONS: PLOT SCALE:
40. 40
Raw
Materials
Title:
Plot Size:
Plot Plan
150m x 95m
800-MAST-B01
Reformer Furnace,
WGS Reactor,
& Phase Separators
Boiler Configuration
CompressorsSulfur Scavenging Heat Exchangers
Maintenance & Operations
Vehicle Parking PSA
Flue Gas
Stack
H 2P En er g y DWG NO:
Hydrogen to Refinery
44. Fixed Capital Investment
44
Unit(s) TMC 2014 CAD
Furnace + Reformer Tubes 8,015,026$
Compressor Water KO 89,956$
Phase Separator Tank 1 169,916$
Phase Separator Tank 2 123,897$
PSA Buffer Tank 95,578$
BFW Tank 161,998$
WGS Reactor 144,373$
PSA Vessels 3,320,586$
Sulfur Scavenging Vessels 799,606$
Natural Gas Compressor(s) 13,334,995$
Pump(s), Reboiler Loop 51,002$
Pump(s), BFW Loop 38,579$
NG preheater/post WGS cooler 1 350,624$
BFW preheater/post reforming cooler 638,017$
BFW preheater/post WGS cooler 2 813,308$
BFW preheater/post WGS cooler 3 2,402,955$
Syngas for PSA cooler 1,960,544$
Flue Gas Stack 104,254$
Combustion Air FD Fan(s) 57,756$
Flue Gas ID Fan(s) 44,275$
Piping (56% of all equipment cost[4]) 18,321,658$
TOTAL MAJOR EQUIPMENT COST 51,038,903$
Building Water Systems 3,623,762$
Instrumentation and Control 4,083,112$
Electrical Systems 4,083,112$
Buildings and Structures 4,695,579$
FIXED CAPITAL INVESTMENT 67,524,469$
45. Annual Operating Costs
45
Parameter Quantity Reference Literature
Operational days/ year 350 As stated in the project
contract
Plant Efficiency (%) 90 44
UTILITIES
Natural Gas Price (2014 CAD $/GJ) 4.5 16
Process Requirements (GJ/year) 6.47 x 106
VMG, 90% efficiency
Fuel Requirements (GJ/year) 3.59 X 106
VMG
Total Natural Gas Costs (2014 CAD MM$/year) 45.38
Electricity Price (2014 CAD $/kWh) 0.08 45
Electricity Load (GWh/year) 19.4 61, adjustment factor
Total Electricity Costs (2014 CAD MM$/year) 1.55
Water Price (2014 CAD $/1000 gallons) 0.5 44
Process Requirements (MMgal/year) 224.1 VMG
Cooling Requirements (MMgal/year) 135.4 VMG
Total Water Costs (2014 CAD MM$/year) 0.18
Total Utility Costs (2014 CAD MM$/year) 47.11
