GREEN HYDROGEN INSTALLATION

CONSIDERATIONS

Presented at GSTC Fall Meeting in San Antonio, TXOctober 11, 2021

byDominic M Varraveto & Chris Ploetz

Agenda

► Introduction & Background• Hydrogen Characteristics: Colors, Safety etc• Experience Integrating Hydrogen Plants• Hydrogen Technology Color Evolution

► Installing Green Hydrogen • Process Description• Basis: Setting the boundary between ISBL & BOP• Input Streams : Feedstock(s), Energy, Utilities• Output Flows: Product(s), By-products, Waste • Infrastructure: Connecting all the Pieces & Auxiliary Systems and • Project Experience

Question: What Color is your Hydrogen? Answer: It depends!

Hydrogen is the smallest and lease dense of all known molecules. At ambient conditions it is a colorless, diatomic gas that burns with a nearly invisible flame.

The color spectrum of visible light has recently been used to classify hydrogen by origin and reaction pathway.

However, hydrogen safety is colorblind and must account for extreme physical properties:

• Gas S.G.= 0.0696• Liquid Density = 4.423 lb/ft3• Boiling Point = -423 deg F• Flammability Range: 4 to 75 % by vol• Transport Fuel Pressure Range: 12k-15k psi

Hydrogen Spectrum

A quantitative alternative to colors is Carbon Intensity or CI, score: amount of CO2attributable to gathering, processing and consuming a fuel per energy released in g/MJ

SMR/Gray Hydrogen Experience

Client Location Project Name Technology

CVR WynnewoodMSAT 2 (included new Hydrogen plant) HydroChem

CVR Coffeyville New Hydrogen Project CB&I

Phillips 66 Billings VIP, Plant #1 Expansion UOP

Phillips 66 BorgerCoker & VDU Revamp (Hydrogen plant) Howe Baker

Phillips 66 Ponca CityULSD (included new Hydrogen plant) Howe Baker

Phillips 66 Ponca CityULSG (included new Hydrogen plant) Howe Baker

Phillips 66 Ponca CityGasoline Benzene Reduction (PSA) UOP

Praxair La Porte PSA Upgrade/Tailgas Compressor UOP

Praxair Plaquemine New PSA Unit UOP

Praxair Texas City 3rd Hydrogen Compressor Linde

Valero Memphis New Hydrogen Plant Technip

Valero McKee New Hydrogen Plant Technip

Hydrogen Installations Considerations

• Integration

• Intermittency

• Infrastructure

• Incentives

SMR/Gray Hydrogen Plant Integration Experience

Qualifications

Burns & McDonnell has extensive experience engineering and constructing “brownfield” SMR Hydrogen plants for existing refineries and Industrial hydrogen suppliers

Hydrogen Technology Color Evolution

Color Origin Pathway/Process Certified CI score1

Gray Hydrocarbon Naphtha, Nat Gas & Steam

Catalytic reforming

150-1662

Blue Nat Gas & Steam

Catalytic reforming w/CCUS

NA ?

Green Water Electrolysis 0.0

1. California Air Resource Board - LCFS Pathway Certified Carbon Intensities2. Includes logistics to compress, liquify and transport feed and product

INSTALLINGGREEN HYDROGEN

Process Description - Electrolysis► Chemistry

• 2H2O + Electricity à 2H2 + O2

§ Requires significant electrical input to drive the reaction

► Types• Alkaline

§ Lower cost at scale§ Well established technology

• Proton Exchange Membrane§ Faster ramp rates§ Less auxiliary equipment§ No Caustic Solution

• Solid Oxide§ Developing technology§ High efficiency

PEM ElectrolysisUS Dept of Energy

Alkaline ElectrolysisKamaroddin, et al

Solid OxideEnergy.nl

Inputs

US National Renewable Energy Laboratory

► Renewable Electricity• Green Hydrogen requires 100% Renewable

Electricity§ Electrolyzer H2 from Grid Energy has

higher CI than typical SMR (gray)• Electricity consumption is high

§ 10 MW Train à 2 MMSCFD H2

• What to do when not available?§ Energy Storage § Hydrogen Storage

► Water• High quality water required

§ Better than BFW• Typically RO required

Renewable Electricity - Availability

► Renewable Electricity can be highly variable• Especially true if onsite wind / solar

► If Green H2 consumption is continuous• Energy Storage

§ Can be offsite by utility• H2 Storage

§ Double or triple electrolyzer capacity and add H2 storage

► Consider if combo solution is feasible• Green H2 / Gray H2 mix has lower CI than

Electrolysis H2 from Grid Average Electricity

US National Renewable Energy Laboratory

US National Renewable Energy Laboratory

Outputs► Products

• Green Hydrogen§ PEM: 99.999%+ purity§ Alkaline: 99.9%+ purity,

– Additional purification to reach 99.999% purity§ Both may require downstream dehydration depending on application (e.g., vehicle fueling)

► Byproducts • Oxygen

§ 99.5% purity§ Consider if potential for use onsite

– E.G., oil refinery FCC or sulfur plant► Waste

• RO reject water• Spent caustic solution (alkaline)

► Reject Heat

Auxiliary Systems

Electrolyzer

Cooling

Water Treatment

Wastewater Treatment

H2 Compression?H2 Liquefaction?

H2 Storage?

Renewable Electricity Power Storage?

H2 Consumption

Auxiliary Systems - Summary► Electrical Infrastructure

• Onsite vs Purchased Renewable Energy• Energy Storage

§ Battery or Supercapacitor► Water Treatment

• If starting from city water, expect ~40% reject• Feedwater impurities (TDS/TSS) accumulate in the stack, so need to be minimized

► Cooling• Up to ~40% of the rated power is rejected as heat

► Compression• To storage pressure or usage pressure• GH2 storage pressure is typically high: ~6,500 psig• GH2 vehicle fueling is 10,000 – 15,000 psig

► Liquefaction► Storage

Project Experience – Gas Utility

► 0.4 MMSCFD Green Hydrogen► 2.5 MW Containerized PEM

• Continuous H2 Consumption§ Electrolyzer operates ~80% of

the time to avoid peak hours§ Requires H2 Storage

• Consumed as § NG fuel blendstock§ Fleet car fueling

• Packaged with Water Treatment and Cooling systems

► 2.5 MW of Green Electricity• Offsite generation

Project Experience – Refinery SMR Alternative

►10 MMSCFD Green Hydrogen►~5 x 10 MW Trains

• Requires continuous H2 production• Centralized Water Treatment and

Cooling systems►~55 MW of Green Electricity

• Offsite generation• Challenging infrastructure and

procurement problem

Q & A