Hydrogen Technology Brochure

8/12/2019 Hydrogen Technology Brochure

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Hydrogen


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HYDROGEN

Technology Leader

As the global leader in engineering and contracting forsynthesis gas technologies, Air Liquide Global E&CSolutions can build on vast experience in engineering,procurement and construction of hydrogen plants.Focusing on customized solutions that reect individualclient and project requirements, Air Liquide Global

E&C Solutions provides the full range of services fromtechnology packages to ownership of large scaleindustrial lump sum turn key projects.

In addition to our outstanding experience of designingover 110 steam methane reforming (SMR ) units world-wide, the integration of S/U experience, the results ofsignicant R&D efforts and the long term operationalexperience led from conventional SMR to the proprietarydesign of todays Lurgi Reformer technology.

Safety and Environment Air Liquide Global E&C Solutions hydrogen plants aredesigned to meet the most stringent international safetyand environmental standards throughout the design,construction and operation of the plant.

Customized Solutions

The majority of hydrogen produced worldwide isconsumed in reneries and petrochemical industries.Hydrogen is also used as transportation fuel and for alarge number of industrial processes such as theproduction of metals, electronics, edible fats and oils,or production of oat glass.

This variety of establ ished and future oriented hydrogenofftakers leads to solid growth rates in global hydrogendemand, of which today more than 95 % is covered byunits applying SMR of hydrocarbon feedstocks.

Renery and chemical companies have various optionsto cover hydrogen demands including: Recovering hydrogen from renery fuel gas or chemical

unit off-gases Revamping existing steam reforming units Building and operating a new steam reforming units Opting for an alternative hydrogen production

method such as gasication technology Importing hydrogen over the fence from an industrial

gas supplier

With cutting-edge

technologies and servicesto dene your solution.

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For all options, Air Liquide Global E&C Solutionscommands the full range of engineering services todevelop the optimum technology solution for theindividual client concept.

The pro ject specic customization process for LurgiReformer typically includes: Closest cooperation with client representatives

Optimization of export steam ows with regards tocost and efciency

Optimization of the integration of new units intoexisting site concepts

Optimization of the generic plant concept, e.g. withregard to co-generation of complementary productssuch as CO, NH 3 or MeOH

Optimization of project implementation schedule Optimization of plant pre-fabrication and modular -

ization concepts Optimization of plant design with regard to multiple

feedstock utilization Optimization of plant availability and reliability with

regard to capital expenditure

In a nutshell the Lurgi Reformer technology provides: Proven technology Highly customized design solutions Easy and smooth operation Superior ring and load control Best in class emission levels

The Lurgi Reformer is especially outstanding due to:

Top red reformer box High energy ef ciency Operational availability higher than 99 % High operational reliability ensured by 2 out of

3 voting systems Optimized turn-around cycles Low utility consumption Low maintenance costs Low overall capital expenditure

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The generic process scheme comprises feed desulfur-ization, SMR, shift conversion and hydrogen purication.

The hydrocarbon feedstock is mixed with recycledhydrogen. Desulfurization comprises two processsteps, organic sulfur compounds are converted to H 2 Sin the presence of a hydrogenation catalyst andH2S is adsorbed.

The desulfurized feed is mixed with process steam atan optimized steam to carbon ratio and superheatedprior to entering the primary reformer. In the presenceof a catalyst the mixed feed is converted to a reformedsynthesis gas containing H 2, CO 2, CH 4, N 2 and steaminside the tubes of the primary reformer.

The CO in the reformed synthesis gas is water gas shifted for increased hydrogen yields by means of sweet watergas shift process units such as high temperature shiftor high temperature shift plus low temperature shiftprocess units.

In the hydrogen purication unit, hydrogen is separatedfrom the shift gas stream by pressure swing absorptionor membrane units to provide continuous and constanthydrogen product ow rates.

The reformer box is heated by ring the off-gas from thehydrogen purication unit and by make-up process fuelwith forced draught burners in the top section.

The combustion air required is routed by a combustionair fan to the burners after pre-heating. The hot uegases exit the reformer box through a refractory-linedduct and are routed to the ue gas stack after excessheat being recovered in the heat recovery section.

Steam generated by waste heat of reformed gas fromthe SMR is utilized as process steam while the excess

is exported.

Process Scheme

Heat Recovery

FeedFuel

HYDROGEN

Desulfurization

Pre-reforming(optional)

Steam Reforming

Shift Conversion

Pressure SwingAdsorption (PSA)

Export Steam

Process Steam

DemineralizedWater

Flue Gas

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To achieve an optimum customization of the LurgiReformer plant design, Air Liquide Global E&C Solutions offers a full range of process options.

Pre-Reforming

For the conversion of higher-molecular hydrocarbons

and optimization of overall energy efciency, Air LiquideGlobal E&C Solutions offers tailor-made pre-reformingprocess units as an integral part of the hydrogen plant.

Autothermal Reforming

Pure autothermal reforming can be applied for syngasgeneration whenever light natural gas and oxygen areavailable as feedstocks. The desulfurized and optionallypre-reformed feedstock is reformed with steam to syn-thesis gas at high pressures using oxygen as reformingagent. The process yields carbon-free synthesis gasand offers great exibility over a wide operating range.

The synthesis gas is compressed by a single casingcompressor with integrated recycle stage to the requiredbattery limit pressure.

As the industry leader in autothermal reforming, wepresent a large number of plant references starting asearly as the 1950s.

Combined Reforming

For heavy natural gases and oil-associated gases, themost economic way to produce synthesis gases is acombination of autothermal reforming and steamreforming. After desulfurization, a branch of the feedgas is processed in a steam reformer at high pressureand relatively low temperature. The reformed gas is then

mixed with the bypassed feed gas and reformed tosynthesis gas at high pressure in the autothermal reformer.

This concept has become known as the Lurgi CombinedReforming process.

The main advantages of the this Combined Reformingprocess is the feed gas bypass of the steam reformerand the low process steam consumption translating intoreduced energy consumption as well as lower capitalexpenditure.

Process Options

Looking back on decades

of operational expertise, wedevelop competitive solutionsfor our customers.

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Success through Technology

Partial Oxidation

Air Liquide Global E&C Solutions proprietary MultiPurpose Gasi cation MPG technology is suited for thenon-catalytic partial oxidation of solids, gaseous orliquid feedstocks for the production of large quantities ofsynthesis gas. With over 45 years of active experiencein gasication technologies and over 75 units on-stream,

Air Liquide Global E&C Solutions is the right par tner tomaximize advantages of the MPG technology due to: Maximum feedstock exibility Extended guaranteed burner lifetimes Inherent plant safety by pressurized cooling water

system Long reactor lifetimes due to moderate, uniform

wall temperature proles Sophisticated designs for boiler and quench

conguration

In combination with raw gas shift and raw gas purication technologies, MPG is the superior choice for largescale hydrogen plants based on heavy residue feed-stocks such as oil sands, vacuum residues, visbreakerresidues or asphalt.

Water Gas Shift

Depending on the process optimization with regard tosteam requirement, feedstock type and quality, and fuelvaluation, Air Liquide Global E&C Solutions proposesthe optimum solution for water gas shift systems:

For hydrogen plants designed for boiler mode operationby sweet water gas shift process units with upstreamfeedstock desulfurization: High temperature shift followed by a hydrogen

purication High temperature shift followed by a low temperature

shift and methanation process steps Medium temperature shift followed by a hydrogen

purication

For hydrogen plants designed for quench modeoperation by a raw gas shift process unit followed bya synthesis gas.

Hydrogen Purication

Depending on process conditions, required hydrogenquality and plant capacity, Air Liquide Global E&CSolutions offers three options for the hydrogen purication process step: Pressure swing adsorption (PSA) as the standard

solution Low temperature shift plus downstream methanation

process units for hydrogen plants with high hydrogenyields

Membrane units for low capacity hydrogen units orhydrogen units with specic quality requirements

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Lurgi Reformer

The heart of the hydrogen plant is the LurgiReformer . Air Liquide Global E&C Solutionsadvanced design combines outstandingoperational characteristics with excellentmaintenance features leading to superioroperability and low investment and operating

costs.

Distinct features of the Lurgi Reformer proprietary design are: Large single train capacities of up to

1,000 tubes per train available Top red reformer box for minimum

number of burners Horizontal convection section for

reduced maintenance efforts Cold header design for minimized

thermal stress and refractory protection Flexitube design for higher design and

operating temperatures Counter-weight tube support design for

minimized mechanical stress Horizontal or vertical waste heat recovery

system designs available High modularization levels for increased

quality of mechanical equipment,piping and instrumentation

Lurgi Reformer

Steam Generation

Reformed Gas Collector

Combustion Air

Reformer Feed

CO 2 Capture

Our proven and worldwide recognized technologyportfolio of CO 2 capture technologies include physicalor chemical washes such as: Rectisol MDEA Amine washes

Emission Control

Reecting increased requirements of environmentalregulations and clients or project policies, Air LiquideGlobal E&C Solutions offers a toolbox of technologiesto lower the environmental impact of hydrogen plantoperations which includes: State of the art noise abatement In-house portfolio of worldwide recognized CO 2

capture technologies Inherent plant safety by pressurized cooling water

system Expertise in NOx reducing burner technologies Latest generation of selective catalytic reduction

technologies (SCR) to minimize nitrous oxide uegas emissions

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Air Liquide Global E&C Solutions is setting best in classstandards with regards to plant availability and reliability by: Integrating design experience from over 110 Lurgi

Reformer units and over 1 million hours of operationin more than 30 Air Liquide hydrogen plants.

Conducting extensive availability studies during thedesign phase of each project

Typical designs resulting in on-stream factors larger

than 99 % for normal operation Proven designs for turn-around cycles of up to

5 years

Hydrogen Quality

The hydrogen produced is of high purity 99.999.999 vol. % , with low impurity levels, such as a CO content below10 vol. ppm.

Utility ConsumptionFor a Lurgi Reformer based medium sized hydrogenplant utilizing light natural gas as feedstock, typicalconsumption gures per 1,000 Nm 3 hydrogen productamount to:

Feed and Fuel 400 420 Nm 3 Make-up BFW 1.01.5 tCooling Water 2.53.0 Nm 3 Electricity approx. 17 kWhExport Steam 0.600.90 t

Typical consumption gures vary depending on hydrogenquality, customization and optimization of the plant

design and export steam valuation.

Load Control

Fully automatic blend and change of various feed -stocks

Fully automatic load changes up to 3 % capacityper minute

Operation at minimum steam to carbon ratios

Firing Control Peaks of PSA tail gas ow and composition are

compensated by fuel gas Stable reformed gas temperature ensured Minimum oxygen content in the ue gas ensured

Availability and Reliability

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Cost Efciency

Lurgi Reformer technology is the result of optimizationand customization processes with regard to capital andoperational cost.

The Lurgi Refomer offers reduced capital expendituredue to:

Top red designs Multiple tube rows limiting the number of burners Large single train plant capacity High level pre-fabrication and modularization

Lurgi Refomer design results in reduced operatingcost due to: High operating pressures at the Lurgi Reformer

outlet High feed preheating temperatures Completely maintenance free catalyst tube

inspection system

Advanced Hydrogen Management

Advanced hydrogen management systems are the keyto hydrogen plant efciency and availability. The LurgiReformer features the most sophisticated controlsystems resulting in exceptionally high on-stream factors.

PRO-EN Services

Pro tability enhancement services are the backboneof hydrogen optimization and management solutions.Customized, proprietary state of the art simulationsoftware offers industry-leading hydrogen optimizationstudies that are customized to meet client and projectneeds and budgets.

Design Tools

Air Liquide Global E&C Solutions applies state-of-the-artplant engineering and software tools such as3D modeling. Computational Fluid Dynamics (CFD)models are used to generate optimized design solutionsat different scales: from the distribution piping tothe full furnace using a dedicated in-house 3D tool.In addition, our multi-scale computational approachhelps creating new mathematical models for complexuid designs.

We design

a true partnership.

CFD Model Sipchen

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References

The benet of long years of engineering experience forsteam reforming plants is available and applied in orderto achieve optimum results.

Plant capacities up to 250,000 Nm 3 / h hydrogenproduction

Worldwide more than 30 hydrogen reference plants Worldwide more than 110 Lurgi Reformer reference

plants Over 120 years of engineering experience

Intelligent Solutions

Around 4,000 employees are working for Air LiquideGlobal E&C Solutions world-wide. More than 15 % areengaged in nding technological solutions in the com-panys technology and R&D units. After all, each clientand each project have their own specic design andoperational conditions calling for intelligent and integrated

concepts. The aspects of feedstock availability and quality are discussed in multidisciplinary teams of experts tooptimize solutions with best-in-class engineering practices.

Process optimizations require concrete numerical data,computer assisted simulation results and considerableexperience. This expertise is indispensible when deci-sions have to be made. Air Liquide Global E&C Solutionscontributes to every project the know-how accumulatedin more than 50 years of engineering experience forsynthesis gas plants.

We design the

worlds most advances innovative solutions.

Operational Excellence

Engineering Center of

Air Liquide Global E &C Solutions

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Competence in Project Execution

Air Liquide Global E&C Solutions execution centersaround the world allow for a fast and efcient support ofclients and projects in their respective location. Moderncommunication structures, fast know-how transfer andthe complete service portfolio are the key to success forour clients and projects.

Scope of Services

Air Liquide Global E&C Solutions provides technologysolutions executed in full-service operating centersworldwide. Our activities cover all phases of synthesisgas projects from nancing through design, procurement,start-up services and operation including:

Consulting services Market studies Conceptual studies Feasibility studies Product marketing Financing Investment analysis Contracting

Value engineering Authority engineering Basic and detail engineering Global sourcing Construction Construction supervision Start-up services Operation and maintenance Technical services

In addition, project management consulting servicesare offered to provide comprehensive project manage-ment and associated services for large scale synthesisgas projects.

About Air Liquide Global E&C Solutions

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E&C Communications, 57 avenue Carnot, BP 313, Champigny-sur-Marne 94503, FRANCE

Air Liquide is the world leader in gases for indust ry, health and the envi ronment , and is present in 80 countrie s with 46,200 employees . Oxygen, nitrogen, hydrogenand rare gases have been at the core of Air Liquides activities since its creation in 1902. Using these molecules, Air Liquide continuously reinvents its business, anticipating theneeds of current and future markets. The Group innovates to enable progress, to achieve dynamic growth and a consistent performance.Innovative technologies that curb polluting emissions, lower industrys energy use, recover and reuse natural resources or develop the energies of tomorrow, such as hy-drogen, biofuels or photovoltaic energy Oxygen for hospitals, homecare, ghting nosocomial infections Air Liquide combines many products and technologies to developvaluable applications and services not only for its customers but also for society.

A partner for the long term, Air Liquide relies on employee commitment, customer trust and shareholder support to pursue its vision of sustainable, competitive growth. Thediversity of Air Liquides teams, businesses, markets and geographic presence provides a solid and sustainable base for its development and strengthens its ability to pushback its own limits, conquer new territories and build its future.

Air Liquide explores the best that air can of fer to preser ve life , stay ing t rue to its Cor porate Social Respons ibilit y and susta inable development approach. In 2011, the Groups revenues amounted to 14.5 billion , of which more than 80% were generated outside France. Air Liquide is listed on the Paris Euronext stock exchange(compartment A) and is a member of the CAC 40 and Dow Jones Euro Stoxx 50 indexes.Copyright Air Liquide Global Engineering & Construction Solutions, 309e Hydrogen / 12.05. / 4

Engineering Centers:

Champigny Air Liquide Engineering57 avenue Carnot, BP 313Champigny-sur-Marne 94503FRANCETel: +33 1 49 83 55 55

Frankfurt

Lurgi GmbHLurgiallee 560439 Frankfurt am MainGERMANYTel: +49 69 58 080

Hangzhou Air Liquide HangzhouNo. 1-1Miao Chang Qiao RoadGouzhuang Industrial Park

Yuhang District Hangzhou 311112CHINATel: +86 571 89 01 91 18

Harima ALEJ16, Niijima, Harimo-choKako-gun, Hyogo-pref675-0181JAPANTel: +81 07 94 37 27 14

Houston ALPC2700 Post Oak Boulevard Suite 1800Houston TX 77056USATel: +1 713 624 8000

Hyderabad ALEIPlot no. 6, APIIC Layout

Hitech CityHyderabad 500 081INDIATel: +91 40 44 99 61 11

JohannesburgLurgi Pty ltdLurgi PlaceTurnberry Ofce Park 180 Cumberland AvenueBryanston 2161SOUTH AFRICATel: +27 11 2 44 46 00

KrakowLurgi S.A.UL; Mogilska 4131-545 KrakowPOLANDTel: +48 12 6 27 22 00

LortonH2Gen7908 Kincannon Place

Ste. ALorton VA 22079United States of AmericaTel: +1 703 339 1495

MemphisLurgi Inc6760 Poplar AvenueSuite 720Memphis TN 38138USATel: +1 901 756 8250

Montreal ALPC Canad a5125 du TrianonSuite 200Montreal Quebec H1M2S5CANADATel: +1 514 798 5590

New DelhiLurgi India Company Private Limited

A24/10 Mohan Cooperat iveIndustrial Estate Mathura RoadNew Delhi 110 044INDIATel: +91 11 42 59 50 50

Russia/CIS Air Liquide Vostok 17 Ulitsa VorontsovskayaMoscow 109147

RUSSIATel: +7 49 56 41 28 98

Russia/CISLurgi GmbH19, Taganskaja StreetFloor 5th

Moscow 109147RUSSIATel: +7 499 272 27 52

Shanghai ALENSA A3, Cao He JingModern Service High-Tech Park No. 1528 Gu Mei RoadShanghai 200233CHINATel: +86 21 60 90 36 88

Vitry

Air Liquide Engineering4 rue des Fusills94781 Vitry-sur-SeineFRANCETel: +33 1 45 73 66 66

Manufacturing Workshops

Hangzhou Air Liquide HangzhouSanliyang, North Gongchen BridgeNo. 398 Shixiang RoadGongshu DistrictHangzhou 310015CHINATel: 86 571 89 01 91 18

Hyderabad ALEIPlot No 12 & 13IDA MallapurNacharamHyderabad 500 076INDIATel: +91 40 2346 1731

Vitry Air Liquide Engineering18 Quai Jules GuesdeVitry-sur-Seine 94407FRANCETel: +33 1 48 82 66 64Business Ofces

BeijingBeijinng Lurgi EngineeringConsulting Co. LtdUnit 0408, Landmark Tower 28 North Dongsanhuan RoadChaoyang DistrictBeijing 100004CHINATel: +86 10 65 90 67 97

Middle East ALEMESuite No 829, West Wing 4B Block Dubai Airport Free Zone,PO Box 54368, DubaiUAETel: +971 42 99 34 44

C/O Al-Jomaih Holding Co.

APSA Al-Jomaih Building5th Floor King

Abdulaziz (Old Airpor t) RoadPO Box 132, Riyadh 11411UAETel: +966 1 47 82 100

Singapore Air Liquide Engineering Sou th Asia3 International Business Park, #03-22Nordic European Center609927SINGAPORE

Sao PauloLurgi do Brasil InstalaonesIndustriais Ltda

Av.Brig. Faria Lima2369-19 andar 01452-000Sao Paulo-SPBRAZILTel: +55 11 30 38 06 00

Cryogenic Equipment Centers

CryopalParc Gustave Eiffel8 rue Gutenberg77607 Bussy Saint GeorgesFRANCETel: +33 1 64 76 15 00

Cryolor3rd Floor, Business Center 1&2

AsianaChennai 600619INDIATel: +91 44 24 99 23 08

CryolorCryolor SAZI Les Jonquires, BP 7Ennery 57365FRANCETel: +33 3 87 70 85 50

Hydrogen Technology Brochure

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