Detailed Project Report (DPR) on Hydrogen Production (99.9% Pure) and Oxygen as by Product (Cap: 21,360 Kg/Day)

HYDROGEN PRODUCTION (99.9% PURE) AND OXYGEN AS BY PRODUCT (CAP: 21,360 KG/DAY)

[EIRI/EDPR/4490] J.C.: 2706XL

Hydrogen can be produced from diverse, domestic resources, including fossil fuels, biomass, and water electrolysis with electricity. The environmental impact and energy efficiency of hydrogen depends on how it is produced. Several projects are underway to decrease costs associated with hydrogen production.

There are several ways to produce hydrogen:

Natural Gas Reforming/Gasification: 

Synthesis gas—a mixture of hydrogen, carbon monoxide, and a small amount of carbon dioxide—is created by reacting natural gas with high-temperature steam. The carbon monoxide is reacted with water to produce additional hydrogen. This method is the cheapest, most efficient, and most common. Natural gas reforming using steam accounts for the majority of hydrogen produced in the United States annually.

A synthesis gas can also be created by reacting coal or biomass with high-temperature steam and oxygen in a pressurized gasifier. This converts the coal or biomass into gaseous components—a process called gasification. The resulting synthesis gas contains hydrogen and carbon monoxide, which is reacted with steam to separate the hydrogen. 

COST ESTIMATION

Plant Capacity            21,360 KG/Day  

Land & Building (40,000 sq.mt.)    Rs. 24.00 Cr    

Plant & Machinery                    Rs. 302.93 Cr 

Working Capital for 1 Month    Rs. 12.22 Cr 

Total Capital Investment          Rs. 343.91 Cr 

Rate of Return                          35%

Break Even Point                      58%

CONTENTS

INTRODUCTION

THERE ARE SEVERAL WAYS TO PRODUCE HYDROGEN:

NATURAL GAS REFORMING/GASIFICATION:

ELECTROLYSIS:

RENEWABLE LIQUID REFORMING:

FERMENTATION:

SEVERAL HYDROGEN PRODUCTION METHODS ARE IN DEVELOPMENT:

HIGH-TEMPERATURE WATER SPLITTING:

PHOTOBIOLOGICAL WATER SPLITTING:

PHOTOELECTROCHEMICAL WATER SPLITTING:

DISTRIBUTION OF HYDROGEN

CURRENTLY, HYDROGEN IS DISTRIBUTED THROUGH THREE METHODS:

PIPELINE:

HIGH-PRESSURE TUBE TRAILERS:

LIQUEFIED HYDROGEN TANKERS:

DETAILS OF ELECTROLYSIS FOR HYDROGEN PRODUCTION

POLYMER ELECTROLYTE MEMBRANE ELECTROLYZERS

ALKALINE ELECTROLYZERS

SOLID OXIDE ELECTROLYZERS

GLOBAL MARKET OVERVIEW OF HYDROGEN

REGIONAL INSIGHTS

FUTURE OF GREEN HYDROGEN

POTENTIAL FOR GREEN HYDROGEN ADOPTION IN INDIA

POTENTIAL ROADMAP FOR GREEN HYDROGEN ADOPTION IN INDIA

(SOURCE: NITI AAYOG)

INTERNATIONAL CLIMATE SUMMIT:

HYDROGEN FUEL TRAINS:

HYDROGEN FUEL BUSES:

GREEN HYDROGEN MOBILITY PROJECT:

FUTURE OUTLOOK

PRODUCTION OF HYDROGEN USING DIFFERENT FEED STOCK

HYDROGEN FROM FOSSIL FUELS

PRODUCTION FROM NATURAL GAS

TABLE: COMPARISON OF TECHNOLOGIES FOR H2 PRODUCTION

FROM NATURAL GAS

PRODUCTION FROM COAL

HYDROGEN FROM SPLITTING OF WATER

WATER ELECTROLYSIS

FIGURE: FUTURE POTENTIAL COSTS OF ELECTROLYTIC HYDROGEN

ALKALINE ELECTROLYSIS

FIGURE: PROCESS DIAGRAM OF ALKALINE ELECTROLYSIS

POLYMER ELECTROLYTE MEMBRANE (PEM) ELECTROLYSIS

HIGH-TEMPERATURE ELECTROLYSIS

PHOTO-ELECTROLYSIS (PHOTOLYSIS)

FIGURE: PRINCIPLE OF PHOTO-ELECTROLYTIC CELL

PHOTO-BIOLOGICAL PRODUCTION (BIOPHOTOLYSIS)

FIGURE: PRINCIPLE OF PHOTO-BIOLOGICAL HYDROGEN PRODUCTION

HIGH-TEMPERATURE DECOMPOSITION

THERMO-CHEMICAL WATER SPLITTING

FIGURE: PRINCIPLE DRAWING OF IODINE/SULFUR THERMO

-CHEMICAL PROCESS

ELECTROLYSIS FOR H2 PRODUCTION

WATER ELECTROLYSIS:

COMMERCIAL TECHNIQUES WATER ELECTROLYSIS

ALKALINE WATER ELECTROLYSIS

ALKALINE WATER ELECTROLYSER

INSIDE A WATER ELECTROLYSER

SOLID POLYMER ELECTROLYTE ELECTROLYSIS

ALKALINE MEMBRANE CELLS

STEAM ELECTROLYSIS AT 1000OC:

TECHNOLOGIES FOR WATER ELECTROLYSIS

HIGH TEMPERATURE STEAM ELECTROLYSIS (SOEC)

DETAILS OF ELECTROLYSIS

ALKALINE ELECTROLYSIS (AEL)

PROTON EXCHANGE MEMBRANE ELECTROLYSIS (PEM)

SOLID OXIDE ELECTROLYSER (SOE)

ANION EXCHANGE MEMBRANE ELECTROLYSIS (AEM)

METHODS OF WATER TREATMENTS

METHODS OF WATER TREATMENT (REVERSE OSMOSIS):

REVERSE OSMOSIS:

BASIC COMPONENTS OF A COMMON REVERSE OSMOSIS SYSTEM

COLD WATER LINE VALVE:

REVERSE OSMOSIS MEMBRANE:

AUTOMATIC SHUT OFF VALVE (SOV):

CHECK VALVE:

FLOW RESTRICTOR:

STORAGE TANK:

FAUCET:

ADVANTAGES

DISADVANTAGES

ION EXCHANGE RESINS

MINI DM PLANT SPECIFICATIONS:

APPLICATIONS:

ADVANTAGES AND LIMITATIONS

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE

SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

ADDRESSES OF PLANT AND MACHINERY SUPPLIERS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)