Raccoon Mountain Team

Hydrogen Production

Proposal

4-22-98

Outline Problem Statement Flow Diagram Material Balance Equipment Design Economic Analysis Final Proposal

Problem Statement

To design a plant which produces a required amount of hydrogen while minimizing costs and waste streams.

(Rev.3//2-26-98)

Flow Diagram

Desulphuriser Reformer

Heat

Natural Gas

Water

Heat

Desulphuriser Passed over ZnO at 675-750 oF

Primary Reformer Ni catalyst at 1300-1500 oF

Flow Diagram

HighTempShift

H2 (g)

CO2 (g)

PSASystem

CO (g)

HiTemp Shift Fe3O4 catalyst at 650-850 oF

PSA (Pressure Swing Adsorption) System 5 packed w/ molecular sieve adsorbent.

Heat Exchangers (2)

Material Balance (Target)

45%

55%

CH4 + 2H20 --> CO2 + 4H2

CH4 + H20 --> CO + 3H2

CH4 = 1.4 H20

94% completion

5 MW =139000 lbmol H

CO + H20 --> CO2 + H2

Reformer

HiTemp Shift

Equipment Design

Economic Analysis

Reactor 100K gal. stainless steel $215,000

Economic Analysis

Hi Temp Shift Tank 100K gal. stainless steel $175,000

Economic Analysis

PSA System Tank (5) 500 gal. stainless steel

(300psi) $245,000

Economic Analysis Storage Tank (2)

50K gal. 304 stainless steel $120,000

Heat Exchangers (2) 304 Stainless steel w/.75” ODx1in. 1000ft2 area $35,000

Economic Analysis

34%

18%

13%12%

10%

7%

3%

3%

Purchased Equipment $790,000 Service Facilities $434,500

Installation $308,100 Instrumentation $276,500

Piping $244,900 Buildings $173,800

Electrical $79,000 Land $63,200

Economic AnalysisRunning Total $1,580,000

(Direct Plant Costs)

Engineering/Sup. (32%) $252,800 Construction (34%) $268,600

Subtotal $2,101,400

(Direct and Indirect Costs)

Contractor’s Fees (5%) $105,070 Contingency (10%) $210,140

Fixed Capital Investment $2,416,600

Economic Analysis COSTS

$3.50 / 1000cu.ft Natural Gas

$0.45 / 1000gal. H2O

$0.0758 / kwh Electricity

PROFITS

$0.40 / 100cu.ft Hydrogen Gas

Carbon Monoxide

Carbon Dioxide

Economic AnalysisFixed Capital Investment $2,416,600

Estimated Monthly Expenses $9,213,000

Estimated Monthly Profit $9,732,000

Estimated Yearly Profit $6,228,000

Estimated Recovery Period 10 months

Proposal

Economic Analysis

-$2,500

-$2,000

-$1,500

-$1,000

-$500

$0

$500

NOTE: Profits x103

Conclusion