iii

v

vi

ES-1

1

1-1

2

2-1

2.1

Hydrogen Separation Device Process Design

2-1

2.1.1

Updated Assumptions for HSD Design

2-2

2.1.2

HSD Design

2-3

2.2

Hydrogen Fuel Plant

2-3

2.2.1

 Process Description

2-9

2.2.2

Effective Thermal Efficiency

2-11

2.3

Hydrogen Fuel Plant-1112ºF (600ºC) Membrane

2-12

2.3.1

Process Description

2-13

2.3.2

Effective Thermal Efficiency

2-16

2.4

Hydrogen Fuel Plant-572ºF(300ºC) Membrane

2-16

2.4.1

Process Description

2-17

2.4.2

Effective Thermal Efficiency

2-21

2.5

Hydrogen Fuel Plant-1112ºF(600ºC) Membrane and 80 Percent Hydrogen Transport

2-21

2.5.1

Process Description

2-13

2.5.2

Effective Thermal Efficiency

2-16

2.6

Cost Estimating

2-26

2.6.1

Approach to Cost Estimating

2-26

2.6.2

Production Costs (Operation and Maintenance)

2-28

2.6.3

Cost Results

2-29

2.7

Summary and Conclusions

2-33

3

Hydrogen from Coal and Natural Gas Based Plants

3-1

3.1

Cases 1,2 and 3-Hydrogen from Natural Gas Without and With CO₂ Recovery

3-1

3.1.1

Natural Gas Conditioning

3-1

3.1.2

Natural Gas Reformer/Boiler

3-2

3.1.3

Water-Gas Shift Reactor

3-3

3.1.4

Acid Gas Removal

3-3

3.1.5

Hydrogen Purification

3-3

3.2

Cases 4 and 5-Hydrogen from Conventional Coal Gasification without or with CO₂ Removal

3-10

3.2.1

Gasifier

3-10

3.2.2

Air Separation Unit

3-10

3.2.3

Particulate Removal

3-10

3.2.4

Shift

3-11

3.2.5

Sulfur Removal/Hydrogen Purification

3-11

3.3

Summary and Conclusions

3-16

4

Hydrogen Fuel From Wyodak Coal/ Biomass Blend

4-1

4.1

Introduction

4-1

4.2

Process Description

4-4

4.2.1

Gasifier

4-5

4.2.2

Air Separation Unit

4-5

4.2.3

Hot Gas Cleanup System

4-5

4.2.4

Sulfuric Acid Plant

4-7

4.2.5

Hydrogen Separation/Conventional Turbine Expander

4-7

4.2.6

Effective Thermal Efficiency

4-8

4.3

Cost Estimate

4-8

4.4

Summary and Conclusions

4-11

5

References

5-1