FEASIBILITY STUDY OF

PRODUCTION OF
HYDROGEN

BY
MAYANK
SCHOOL OF CHEMICAL TECHNOLOGY
GURU GOBIND SINGH INDRAPRASTHA UNIVERSITY
DWARKA SEC-16C

INTRODUCTION
Hydrogen was first separated and identified in the second half
of the 18th century . From many years the industrials demands
for hydrogen were limited to the relatively small quantities
used in operating oxy-hydrogen lamps used for projection
purpose . However, hydrogen-manufacturing process
developed the last 75 years where primarily for the use in
hydrogen in ammonia and methanol production .Decreasing
coal usage continues to force hydrogen out of the energy
sector, the long term chances for its return remain good as long
as its advantages of renewable production and carbon-free
nature continue to be demanded . The move to a large scale
hydrogen based energy sector will also be seen as an important
option when the contribution by fluctuating generation
electricity producers (Wind,Solar) reaches such a level that the
electricity supply and demand can only be matched with the aid
of a storage mechanism. . Hydrogen presently has the most
attractive properties as a "Storage Medium" of electricity.

The advantages of no pollution and reduced fuel weight

are however coupled with an increase in the volume
and weight of the required fuel tank, which for small
vehicles would lead to a reduction in range and
payload. A low cost introduction and testing phase can
take place in the surroundings of conventional chemical
hydrogen production. Within the next five to ten years,
this should lead to an economical market penetration
that could be sustainably extended in the medium-term
with imported hydrogen and other hydrogen sources
(e.g. biomass gasification). In 1800 first production of
hydrogen and oxygen by electrolysis and after that in
1898 liquefaction of hydrogen using linde process was
done. In 1902 first commercial electrolysis installation
was done. In 1954 led the ignition of the first hydrogen
bomb on the bikini atoll (USA). In 1955 hydrogen was
started using as energy carrier medium

Properties of Hydrogen
HYDROGEN IS LIGHTEST AN SIMPLEST OF ALL ELEMENTS. IT
IS FAIRLY BUT NOT EXCEPTIONALLY REACTIVE GAS. IT ENTERS
INTO CHEMICAL COMBINATION WITH MOST OF THE ELEMENTS
AND HYDROGEN FORMS MORE COMPOUNDS THAN ANY
OTHER ELEMENT. THE DIFFERENCE IN THE MASSES OF
ISOTOPES IS RELATIVELY LARGE, SO THAT THERMODYNAMICS
PROPERTIES DIFFER CONSIDERABLY. HYDROGEN GAS IS
COLOR LESS, NON POISONOUS ODORLESS AND TASTELESS.
CONTRARY TO MOST OTHER GASES, THE INVERSION
TEMPERATURE OF HYDROGEN LIES BELOW AMBIENT
TEMPERATURE. LIQUID HYDROGEN IS COLORLESS, VERY
MOBILE LIQUID WITH LOW VISCOSITY AND SURFACE TENSION.

The chemistry of hydrogen depends mainly on three processes,

1. Loss of the valency electron to yield the hydrogen ion H+
2. Gain of an electron to form the hydride ion H3. Formation of an electron pair bond.
4.Hydrogen is not exceptionally reactive, although hydrogen atoms
with all other elements with the exception of noble gases.
5.The strength of the H X bond in covalent hydrides depends on
the electro-negativity and size of the element X.
6.The strength decreases in a group with increasing atomic number
and generally increases across any period.
7.The most stable covalent bond are those formed between two
hydrogen atoms, or with hydrogen, oxygen carbon and nitrogen

USES OF HYDROGEN
1. AMMONIA SYNTHESIS
2. HYDROGEN IN REFINERY PROCESSES
3. HYDROGEN IN COAL REFINEMENT
4. HYDRO PYROLYSIS.
5. HYDRO GASIFICATION OF COAL.
6. METHANOL SYNTHESIS.
7. FISCHER-TROPSCH SYNTHESIS
8. METHANE SYNTHESIS
9. HYDRO FORMULATION OF OLEFINS
10. HYDROGEN IN ORGANIC SYNTHESIS.
11. HYDROGEN IN INORGANIC SYNTHESIS
12. HYDROGEN IN METALLURGY
13. HYDROGEN IN NON-FERROUS
METALLURGY.

INDUSTRIAL USES
1.FOOD TO HYDROGENATE LIQUID OILS (SUCH AS SOYBEAN, FISH,
COTTONSEED AND CORN), CONVERTING THEM TO SEMISOLID
MATERIALS SUCH AS SHORTENINGS, MARGARINE AND PEANUT
BUTTER.
2. PHARMACEUTICALS TO PRODUCE SORBITOL USED IN
COSMETICS, ADHESIVES, SURFACTANTS, AND VITAMINS A AND C.
3. AEROSPACE TO FUEL SPACECRAFT, BUT ALSO TO POWER LIFESUPPORT SYSTEMS AND COMPUTERS, YIELDING DRINKABLE WATER
AS A BY-PRODUCT.
4. ELECTRONICS TO CREATE SPECIALLY CONTROLLED
ATMOSPHERES IN THE PRODUCTION OF SEMICONDUCTOR CIRCUITS.
5. PETROLEUM RECOVERY AND REFINERY TO ENHANCE
PERFORMANCE OF PETROLEUM PRODUCTS BY REMOVING ORGANIC
SULFUR FROM CRUDE OIL, AS WELL AS TO CONVERT HEAVY CRUDE
TO LIGHTER, EASIER TO REFINE, AND MORE MARKETABLE PRODUCTS

HYDROGEN PRODUCTION
1.HYDROGEN PRODUCTION BY ELECTROLYSIS
ELECTROLYSIS HAS BEEN USED FOR APPROX. 100
YEARS FOR HYDROGEN PRODUCTION. THE FIRST
INSTALLATION WAS BY NORSK HYDRO IN 1927 IN
NORWAY. THE ELECTION OF LARGE ELECTROLYSIS PLANT
GENERALLY DEPENDS ON THE AVAILABILITY OF CHEAP
ELECTRICITY FROM HYDRO POWER STATION. A TOTAL OF
5% OF THE WORLD HYDROGEN PRODUCTION IS BY
MEANS OF ELECTROLYSIS.
THE FOLLOWING REACTION OCCURS AT THE
ELECTRODES

Pure water is not suitable as an electrolyte because of

its very low conductivity. Therefore aq. Solution of
potassium or sodium hydroxides etc are used.

Electrolysis plant:
A part from the electrolysis unit electrolysis plant
consists of number of different Installations. Such as
electricity supply water treatment, electrolyte from
product gases .Gas purification and the instrument and
the control system dedicated thermal electricplants for
the production of hydrogen may build in the future.

Manufacturing of Hydrogen by shell gasification

process
THE PROCESS IS CARRIED OUT BY INJECTING PREHEATED
HYDROGEN, PREHEATED OXYGEN AND STEAM THROUGH A
SPECIALLY DESIGNED BURNER INTO A CLOSED COMBUSTION
VESSEL, WHERE THE PARTIAL OXIDATION OCCURS AT 1290
1400C, WITH LESS THAN STOCHIOMETRIC OXYGEN FOR
COMPLETE COMBUSTION.
1.HEATING CRACKING PHASE: THE ATOMIZED HYDROGEN IS
HEATED AND VAPORIZED BY BACK RADIATION FROM THE
FLAME FRONT AND THE REACTOR WALLS SOME CRACKING TO
CARBON, METHANE AND HYDROCARBONS RADICALS OCCURS
DURING THIS BRIEF PHASE.
2.REACTION PHASE: HYDROCARBONS REACT WITH OXYGEN
ACCORDING TO HIGHLY EXOTHERMIC COMBUSTION REACTION
PARTIALLY ALL OF THE AVAILABLE OXYGEN IS CONSUMED IN
THIS PHASE.

3. Soaked phase: The final phase takes place in the

rest of the reactor where the gas is at higher
temperature. A portion of the carbon disappears by
reaction with CO2 and steam. Some carbon is present
in the product gas.

Equipment: partial oxidation equipment consists

essentially of
1. Gasification reactor.
2. Waste heat exchanger.
3. Economizer heat exchanger.
4. Carbon removal system.
5. CO conversation unit.
6. CO2 absorber unit.

MATERIAL BALANCE

ABSORBER BALANCE

It is assumed that here that only CO2 removal takes place we have
Hydrogen remaining constant and 95% pure after the process.
At inlet of absorption coloumn we have
Gas composition
vol%
kmol
CO2
33.86
48.52
CO
1.60
2.35
H2
63.73
91.74
CH4
0.42
0.60
N2
0.39
0.56

Also since only carbondioxide is removed amount of hydrogen is

constant.

Therefore we have

(63.73/100)x(Y) =1703.97 kmol/hr (amount of hydrogen to be

produced is 1703.97)

kmol /hrof mixture=2650.3442

At inlet of absorption column we have

Gas composition
vol%
CO2
33.68
CO
1.60
H2
63.90
CH4
0.42
N2
0.39

kmol
892.64
42.40
1693.57
11.13
10.33

Now X moles of CO2 is removed, also amount of hydrogen is

constant is constant
Therefore
95/100 = (1703.97)/{(1703.97) +(905.36-X) +(42.68) +(11.3)
+(10.40)}
X =867.64kmol

Gas composition
vol%
kmol
CO2
1.41
24.995
CO
2.38
42.40
H2
95.00
1693.57
CH4
0.63
11.13
N2
0.58
10.33

ENERGY BALANCE
Energy balance for Pre heater
In this feed is heated from initial available temperature
of 50C to 250C
By steam heating steam is available at 600 psig.
Also heat transferred by steam will be used by Feed gas
for heating.
Heat received by gas = n x Cp x T
= 529.62 x 41.75 x 160
= 3537861.6 KJ/h
Heat supplied by steam
Let steam flow rate be M Kg/h
Also , M x s = 3537861.6 KJ/h
M = 0.44 kg/sec
Heat balance for waste heat boiler is given by
In W.H.B gas from reactor are cooled from cold water

Gas Flow rate =1832.48 kmol/h

Gas composition
(vol%))
CP
(kJ/kmolC)
CO2
4.32
70.00
CO
46.55
36.43
H2
47.15
31.768
CH4
0.60
100.48
N2
0.56
36.343
H2S
0.81
neglected

CP of mixture = 35.773 kJ/kmolC

Heat transferred by gas = 1832.48 x 35.773 x 1050
Heat taken by cold water = M x CP x T +M x

We have,
M x CP x T +M x = 1832.48 x 35.773 x 1050
M(4.187 x 80 + 2210) =1832.48 x35.773 x1050
Mass flow rate of cold water = 27045.99 kg/h = 7.51 kg/s

MECHANICAL DESIGN OF
ABSORBER
Material for shell is Carbon Steel

THICKNESS OF SHELL
Thickness of shell = ts
ts = [p D / 2f J p] + c
Hence, ts =3.95mm
We take thickness as 8mm (Including corrosion allowance)
Axial Stress Due to Pressure
Axial stress due to pressure =fap
fAP = P* Di / 4* ( tS c )
= 13.31*106 N/m2
Stress due to Dead Load
a) Compressive Stress due to weight of shell up to a distance X
Do = Di + 2 ts
=2.86 + 2*2*10-3 = 2.864 m
fds = 4 ( Do2 Di2 )s X] / /4 ( Do2 Di2 )
=7.7*103* X N/m2

b) Compressive stress due to weight of insulation at height

X
Insulator used is asbestos
fdins = * Dins tins *ins *X/ Dm ( ts c )
= 9.844*103 X N /m2
c) Compressive stress due to liquid in column up to height X
fdliq = [ ( /4 ) Di2 X l ]/ Dm ( ts c )
= 14.868 x10 5 N/m2
Stress due to Wind
Stress due to wind is given by
fwx = M w / Z
Where, Bending Moment = Mw = (0.7* pw* Do* X2)/2
Z = ( /4) *Do2 *( ts c )
Pressure due to wind = pw = 0.05 x vw2
fwx = 1.4* pw *X2 / Do ( ts c )
= 29.44*103*X2

DESIGN OF GASKET AND BOLT SIZE

Mean diameter = G = (Dfi + Dfo) / 2 = 3.05 m
Under atmospheric conditions, the bolt load due to gasket reaction is
given by Wm1 = b G Ya
= 670.73*103 N
After the internal pressure is applied, the bolt load is given by
Wm2 =(2b) G * m * P + (/4)G2 *P
= 8.375*105 N
Bolt used is hot rolled carbon steel
Am1= Wm1 / fa
Am1= 0.011 m2

Am2 = Wm2 / fb
Am2= 0.0154 m2

Number of bolts = mean diameter /box 2.5 =244 bolts

To determine the size of bolts, the larger of above two areas should be
considered
Diameter of bolts =[(Am2 /Number of bolts) x (4/)]1/2
=0.90 cm

HEAD DESIGN: FLANGED & SHALLOW

Material stainless steel
W = () [3 + ( Rc/R1)1/2]
W is 1.77
Thickness of head = th = (p x Rc W)/(2f)
th= 2.07 mm
So , we can take thickness of head as that of thickness of shell

NOZZLE THICKNESS
Material Carbon steel
tn=P*Dn /(2 f x J P)
tn = 0.24

Stress due to dead load

fd = Total Weight / Ds tsk
= 3.48*105/tsk N/m2

Due to wind load

plw = k p1 h1 Do (for Height less then 20m) for Height less then 20m
Where K is coefficient depending on the shape factor.
k=0.7 for cylindrical
surface
plw = k P1 h1 Do
= 15389.92
Bending moment due to wind at the base of the vessel is determined by
Mw = Plw*H/2
=80027.584 N- m
fwb = 4 x Mw / Do tsk
=35552.78/tsk

Stress due to Seismic Load

Load F= CW
C=0.08
fsb = ( 2/3)[ CWH/ (Rok)2 tsk]
= 2.69*105/tsk N

Maximum Compressive Stress

fcmax = ( fwb or fsb ) + fdb
= (77847.09 / tsk ) N /m2
tsk =9.26 mm

Pollution control and safety

HYDROGEN FORMS INFLAMMABLE AND EXPLOSIVE MIXTURE
WITH OXYGEN AND OTHER ELEMENTS. VOLUMETRIC LEAKAGE
OF HYDROGEN GAS WILL BE 1.3 2.8 TIME AS LARGE AS
GASEOUS METHANE LEAKAGE AND APPROXIMATED FOUR
TIMES THAT OF AIR UNDER THE SAME CONDITIONS.
FIRE HAZARDS:
THE MINIMUM ENERGY FOR IGNITION OF HYDROGEN AIR
MIXTURE IS EXTREMELY LOW. HOWEVER THE IGNITION
ENERGY INHERENT IN VIRTUALLY EVERY SOURCE IS MORE
THAN SUFFICIENT FOR IGNITION OF ANY OTHER FUEL-AIR
MIXTURE. HYDROGEN FLAMES ARE NEARLY INVISIBLE IN DAY
LIGHT ONE OF THE MAJOR CAUSES OF INJURY AND
THEREFORE A MAIN PARAMETER OF FIRE DAMAGE IS
CONSIDERED LESS SERIOUS IN THE CASE OF HYDROGEN
BECAUSE THE SOLE COMBUSTION PRODUCT IS WATER VAPOR.


Explosive hazards:
High laminar burning velocity as well as the high laminar flame
speed of hydrogen makes the transition than hydrocarbons
hydrogen. Explosions are rated in terms of the amount of energy
released, commonly expressed as an equivalent quantity of TNT.
Preventive measures:
In safety concepts, distinction are made between primary secondary
are made between primary secondary and tertiary measures primary
safety precautions aim at the exclusion of causative risks such as
leakage, formation of explosive mixtures. Tertiary measures should
minimize dangerous results in case fire or explosion occurs this is
achieved by installation of explosion proof or explosion relief system,
hydrogen process shutdown systems and suitable fire extinguishing
system.
Safety regulations:
Regulation and standards apply for the safe production, storage and
handling of oxygen they are mostly concerned with transportation,
and other operations are covered by more general regulation safety
regulation in India

Storage:
Conventional methods for storing hydrogen are well proven and in service. Depending on
the end use. Different types of storage systems:
1. Stationary, large size storage systems,
2. Stationary, small size storage systems,
3. Mobile storage systems.
Compressed hydrogen storage:
Pressure storage systems of various sizes and pressure ranges are considered state of the
art. The same applies for temporary storage in pipelines. Low-pressure and high pressure
systems are suitable for the storage of day or week supplies.

Liquid hydrogen storage:

The technique for liquid Hydrogen storage is well developed it is used for storage,
transport, and distribution of hydrogen. The vessels are insulated with double walls.

PLANT LOCATION AND

LAYOUT
The Principal Factors To Be Considered Are:

Location, With Respect To The Marketing Area.

Raw Material Supply.
Transport Facilities.
Availability Of Labour.
Availability Of Utilities: Water, Fuel, Power.
Availability Of Suitable Land.
Environmental Impact, And Effluent Disposal.
Local Community Considerations.
Climate.
Political Strategic Considerations.

The Plant Should Be Located Close To The Primary

Market. This Consideration Will Be Less Important For
Low Volume Production, High-Priced Products; Such
As Pharmaceuticals.

PLANT LAY OUT

The economic construction and efficient operation of
a process unit will depend on how well the plant and
equipment specified on the process flow sheet is laid
out. The principal factors are considered are:
Economic considerations: construction and
operating costs.
The process requirements.
Convenience of operation.
Convenience of maintenance.
Hydrogen Plant Design
Safety.
Future expansion.
Modular construction.

References
[1]http://www.sbioinformatics.com
[2]Energy.gov/eere/fuelcells/hydrogen
[3]En.m.wikipedia.org/wiki/hydrogen
[4]www.iea.org/publication/hydrogen
[5]www.altenergy.org/renewables/hydrogen