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Capital and Operating Cost of Hydrogen Production from Coal Gasification - April 2003

Thomas L. Buchanan
Michael G. Klett
Ronald L. Schoff

National Energy Technology Laboratory

Table of Contents (166kb)

List of Tables iii
List of Figures iii
List of Acronyms and Abbreviations v
 
EXECUTIVE SUMMARY (1.45MB) ES-1

1

 INTRODUCTION (231kb) 1-1
 

1.1

 Background 1-1
 

1.1.1

 Plant Configurations 1-1

1.1.2

 Summary of Plant Differences 1-3

1.1.3

 Financial Assumptions and Cost Data 1-3

1.1.4

 Capital and Operating Costs 1-4

1.1.5

 The Need for Reconciliation of Cost Estimates 1-4

1.2

 Task Objectives 1-5

1.3

 Plant Design Basis 1-6
 

1.3.1

 Plant Capacity and Availability 1-6

1.4

 Process Selection 1-9
 

1.4.1

 Gasifier 1-9

1.4.2

 Shift Reactor Catalyst 1-9

1.4.3

 Acid Gas Removal 1-9

1.4.4

 Hydrogen Purification 1-10

1.5

 Approach to Cost Estimating 1-11
 

1.5.1

 Gasifier 1-11

1.5.2

 Acid Gas Removal 1-11

1.5.3

 Sulfur Recovery and Tail Gas Cleanup 1-11

1.5.4

 Hydrogen Purification 1-12

1.5.5

 Shift Reactors 1-12

1.5.6

 Candle Filters 1-12

1.5.7

 Air Separation Unit 1-12

1.5.8

 Balance of Plant 1-12

2

 PITTSBURGH NO. 8 COAL (3.02MB) 2-1
 

2.1

 Health and Material Balance 2-1

2.2

 Process Description 2-7
 

2.2.1

 Gasifier 2-7

2.2.2

 Air Separation Unit 2-7

2.2.3

 Particulate Removal 2-7

2.2.4

 CO Shift 2-7

2.2.5

 Amine Unit/Acid Gas Concentrator 2-8

2.2.6

 Hydrogen Purification 2-8

2.3

 Major Equipment List for Bituminous Coal Case 2-9

2.4

 Capital Cost 2-15

2.5

 Determination of Cost of Hydrogen from Pittsburgh No. 8 Coal 2-15
 

2.5.1

 Approach to Cost Estimating 2-16

2.5.2

 Production Costs (Operation and Maintenance) 2-16

2.5.3

 Consumables 2-17

2.5.4

 Byproduct Credits 2-18

2.5.5

 Financial Assumptions 2-18

2.5.6

 Cost Results 2-18

3

 WYODAK PRB COAL (2.97MB) 3-1
 

3.1

 Heat and Material Balance 3-1

3.2

 Process Description 3-7
 

3.2.1

 Gasifier 3-7

3.2.2

 Air Separation Unit 3-7

3.2.3

 Particulate Removal 3-7

3.2.4

 CO Shift 3-7

3.2.5

 Amine Unit/Acid Gas Concentrator 3-8

3.2.6

 Hydrogen Purification 3-8

3.3

 Major Equipment List for Wyodak Coal Case 3-9

3.4

 Capital and Operating Costs for Hydrogen from Wyodak PRB Coal 3-16

3.5

 Determination of Cost of Hydrogen from Wydoak PRB Coal Using Preliminary Assumptions 3-16
 

3.5.1

 Approach to Cost Estimating 3-17

3.5.2

 Production Costs (Operation and Maintenance) 3-18

3.5.3

 Consumables 3-18

3.5.4

 Byproduct Credits 3-18

3.5.5

 Financial Assumptions 3-18

3.5.6

 Cost Results 3-19

4

 COST OF HYDROGEN USING THE DOE IGCC FINANCIAL MODEL (122kb) 4-1
 
Appendix A Pittsburgh No. 8 Coal with DOE IGCC Financial Model (5.64MB)
Appendix B Wyodak PRB Coal with DOE IGCC Financial Model (5.54MB)
 
LIST OF TABLES

ES-1

 Design Criteria for Conventional Hydrogen Production Plant ES-3
ES-2 Performance Summary - Hydrogen Production from Pittsburgh No. 8 Coal ES-5
ES-3 Capital Cost Summary - Hydrogen Production from Pittsburgh No. 8 Coal ES-6
ES-4 Performance Summary - Hydrogen Production from Wydoak Coal ES-8
ES-5 Capitol Cost Summary - Hydrogen Production from Wydoak Coal ES-8
ES-6 Financial Parameters ES-10
1-1 Comparison of Parsons and NREL Plants 1-2
1-2 Performance Summary 1-3
1-3 Financial Assumptions 1-3
1-4 Capital and Operating Cost Comparisons 1-4
1-5 Coal Analysis - Pittsburgh No. 8 1-7
1-6 Wyodak Coal Properties 1-8
1-7 Design Criteria for Conventional Hydrogen Production Plant 1-8
2-1 Plant Performance Summary - Hydrogen Production from Pittsburgh No. 8 Coal 2-3
2-2 Process Stream Compositions and State Points - Pittsburgh No. 8 Coal 2-5
2-3 Capital Cost Summary - Hydrogen Production from Pittsburgh No. 8 Coal 2-15
2-4 Operating Cost Data 2-17
2-5 Financial Parameters 2-18
2-6 Capital Investment & Revenue Requirement Summary 2-19
3-1 Plant Performance Summary - Hydrogen Production from Wydoak Coal 3-3
3-2 Process Stream Compositions and State Points - Wyodak Coal 3-5
3-3 Capital Cost Summary - Hydrogen Production from Wyodak Coal 3-16
3-4 Operating Cost Data 3-18
3-5 Financial Parameters 3-19
3-6 Capital Investment & Revenue Requirement Summary 3-20
 

LIST OF FIGURES
ES-1 Block Flow Diagram - Conventional Hydrogen Plant ES-2
ES-2 Sensitivity of IRR to Hydrogen Costs ES-10
1-1 Block Flow Diagram - Conventional Hydrogen Plant 1-5
2-1 Heat and Mass Balance - E-GasTM Gasifier-Based Hydrogen Production Plant - Pittsburgh No. 8 Coal 2-2
2-2 Process Block Flow Diagram - E-GasTM Gasifier-Based Hydrogen Production plant - Pittsburgh No. 8 Coal 2-4
3-1 Heat and Mass Balance - E-GasTM Gasifier-Based Hydrogen Production Plant - Wyodak Coal 2-2
3-2 Process Block Flow Diagram - E-GasTM Gasifier-Based Hydrogen Production plant - Wyodak Coal 2-4
4-1 Sensitivity of IRR to Hydrogen Costs 4-1