HyGenSys

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• - HyGenSys -
• Gas to Hydrogen and Power Process
• Facilitates CO2 Capture to Sequestration

Jérôme COLIN Fabrice GIROUDIERE
IFP
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Outline

• Backdrop
• Steam reforming Hydrogen generation
• Endothermic heat input concept
• The novel gas-to-hydrogen power process
• Reactor development for HyGenSys
• Project status

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Backdrop

• CACHET CArbon Capture via Hydrogen Energy
  Technology

Electrical Power production 400 MWe
Co-generation of H2 Ultimate green fuel
SP1WP 1 to 4 technical solution
Natural Gas plentyful ressources high H/C ratio
Capture of 90 of emitted CO2
CO2 Capture cost lt 20 Euros/ton lower cost than
capture from gas combustion flue gas
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Backdrop

• SP1-WP1 (advanced SMR HyGenSys)

Work Package leader
SP1-WP1 PARTICIPANTS
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IFP conceptual HyGenSys integration scheme

H2 Fired Turbine
POWER
H2 PRODUCTION
H2 rich gas
Natural Gas
SP1-WP1 technical solution
CO2 separation unit
Syngas
Compression
CO2
HyGenSys Hydrogen and Power co-generation process
CO2 SEQUESTRATION
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Outline

• Backdrop
• Steam reforming Hydrogen generation
• Endothermic heat input concept
• The novel gas-to-hydrogen power process
• Reactor development for HyGenSys
• Project status

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Simplified Reaction Chemistry
Steam Reforming
Endothermic Heat
CH4 H2O 3 H2 CO
Water Gas Shift
Exothermic Heat
CO H2O H2 CO2

Resulting required conversion needs large heat
input to be provided
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Hydrogen Generation Concept
Steam Reforming
Water Gas Shift
Natural Gas
Synthesis Gas
Raw Hydrogen
First Reaction
Second Reaction
CH4
H2 CO2
Some residual Steam residual CH4 CO
Steam
H2O
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Outline

• Backdrop
• Steam reforming Hydrogen generation
• Endothermic heat input concept
• The novel gas-to-hydrogen power process
• Reactor development for HyGenSys
• Project status

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Endothermic Heat Input Concept
Water gas shift
Steam reforming
Natural Gas
Endothermic
Exothermic
Raw Hydrogen
Steam
Hot pressurized gas
Very hot pressurized gas
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The Heat Source

• Once through pressurized hot gas from a gas
  generator part of a two-shaft Gas Turbine
• Other possible gas generator
• an off-the-shelf Jet engine
• a gas generator part of an aero-derivative gas
  turbine
• a purpose made air compressor, combustion chamber
  and power expander

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Single Shaft Gas Turbine
Atmospheric Exhaust
HP Fuel Gas
Load
Air
Turbine
Axial Compressor
Single shaft Gas Turbine Assembly
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Split Shaft Gas Turbine
Atmospheric Exhaust
HP Fuel Gas
Load
Air
Compressor Driver Turbine
Axial Compressor
Power Recovery Turbine
Gas Turbine Assembly
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Split Function Gas Turbine
Atmospheric Exhaust
Still Pressurized Very Hot Exhaust
HP Fuel Gas
Load
Air
Compressor Driver Turbine
Axial Compressor
Power Recovery Turbine
Hot Gas Generator
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Split Function Gas TurbineEstimated operating
conditions
1 bar 570C
H2 Rich Gas
5.6 bar 860C
17.5 bar 1142C
25.5 bar 200C
18 bar 400C
Load
1 bar 15C
Hot Gas Generator
Power Recovery Turbine
Modified Siemens SGT-700 for Hydrogen firing
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Outline

• Backdrop
• Steam reforming Hydrogen generation
• Endothermic heat input concept
• The novel gas-to-hydrogen power process
• Reactor development for HyGenSys
• Project status

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Reaction Heat Flow Concept
Steam Reformer
H2 Rich Gas
Post combustion
Air
Natural Gas Steam
SynGas
Hot Gas Generator Modified Siemens SGT-700
Power recovery Turbine Dresser-Rand E-248
expander

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Heating Medium Process Flow
H2 rich gas
Stack Gas
Steam
5 bar 630C
HRSG
Power
4.9 bar 760C
5.3 bar 1290C
Secondary combustion After burner
Tertiary combustion
Hot Gas Generator
Power
Tubular Catalytic Reactor / Exchangers
Expander
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HyGenSys process
Hydrogen rich gas fuel only
CO2 free Flue gas
Air

Hot Gas Generator
Steam
H/E SMR Reactor
HRSG
Steam turbine generator
SH Steam
Expander Generator
BFW
Condensate
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HyGenSys process
Hydrogen rich gas fuel only
CO2 free Flue gas
Air
Shift Converter

H2 / CO2Separation
Hot Gas Generator
H/E SMR Reactor
Natural Gas
water
CO2 for Sequestration
HRSG
Steam turbine generator
SH Steam
Expander Generator
BFW
Condensate
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HyGenSys process
Hydrogen rich gas fuel only
CO2 free Flue gas
Air
Shift Converter

H2 / CO2Separation
Hot Gas Generator
H/E SMR Reactor
Natural Gas
water
CO2 for Sequestration
Air
HRSG
Steam turbine generator
SH Steam
Expander Generator
H2 GT Generator
BFW
Condensate
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HyGenSys Main Features

• Pressurized post combusted Hot Gas Generator
  exhaust provides all reaction heat input
• Tertiary post combusted reactor exit hot gas
  offers substantial expansion power generation
• Hot exhaust offers combined cycle steam power
  generation
• Maximum power generation from excess hydrogen
  fired GT
• Flexible ratio of H2 and Power co-generation

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HyGenSys preliminary performances

• HyGenSys Integration
• 4 HyGenSys units in parallel
• Use of 4 Modified Siemens SGT-700 (Hot Gas
  generators) and 4 Dresser-Rand E-248 (Expanders)
• 1 Siemens SGT5-4000F modified Hydrogen Fired Gas
  Turbine
• CO2 separation with Amine unit
• Resulting performances
• Net power 617 MWe
• CO2 Capture ratio 80
• Overall efficiency 45
• Total pure H2 production 440 000 Nm3/h

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Outline

• Backdrop
• Steam reforming Hydrogen generation
• Endothermic heat input concept
• The novel gas-to-hydrogen power process
• Reactor development for HyGenSys
• Project status

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Reactor development
Hot flue gas
S M R
H2 CO CO2 CH4 H2O
CH4 H2O
Cooled flue gas
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Reactor specific constrains

• Reactor challenges and requirements
• High temperature heat transfer
• Pressurized vessel
• High capacity
• Distribution of feed and flue gas
• Collection of syngas and cooled flue gas
• Easy catalyst management
  (loading and unloading)
• Safety / flexibility in operation

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Reactor development

• Conceptual and feasibility study
• Technology selection
• Reactor arrangement
• Integration in HyGenSys

• Reactor modeling
• Kinetic
• Heat transfer

Cold mock-up
Steam Reforming Reactor

• Material study
• Creep resistance
• Metal dusting and carburization
• Oxidation corrosion

Risk and reliability analysis
Reactor cost estimate
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Reactor development

• Technology highlights
• Original Double pipe / Bayonet tubes concept
• Convection assisted reformer heating
• Refractorized and pressurized shell
• Externalized combustion chamber
• Reactor specifications overview
• External diameter 8 m
• Number of bayonets 300 tubes per reactor

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Outline

• Backdrop
• Steam reforming Hydrogen generation
• Endothermic heat input concept
• The novel gas-to-hydrogen power process
• Reactor development for HyGenSys
• Project status

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Project status

• Completed work
• Process study
• CO2 separation technologies assessment ? Amine
  unit
• HyGenSys integration
• Reactor development
• Concepts selection
• Kinetic and heat transfer model for sizing
• In progress
• Process optimization
• Reactor design validation and cost evaluation
• Overall HyGenSys technology evaluation

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Conclusion

• HyGenSys is a promising process for converting
  gas to hydrogen and power with reduced carbon
  emission
• It reduces the cost of CO2 capture processes
  thanks to a high level of heat integration
• Mostly well proven technologies

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• THANK YOU FOR YOUR ATTENTION