Description of the H2-Plant

2 Description of the H2-Plant

2 Description of the H2-Plant ...................................... 2-1

2.1 Use .............................................................................. 2-2
2.2 System specification .................................................... 2-3
2.3 Appropriate use ........................................................... 2-8
2.4 Technical data ............................................................. 2-9
2.5 Specification of operating media ............................... 2-11
2.5.1 Natural gas ................................................................ 2-11
2.5.2 Nitrogen ..................................................................... 2-11
2.5.3 Instrument air ............................................................ 2-11
2.5.4 Cooling water............................................................. 2-12
2.5.5 Demineralized water .................................................. 2-12
2.5.6 Desulphurization catalyst........................................... 2-12
2.5.7 Reformer catalyst ...................................................... 2-12
2.5.8 HT-CO-reactor filling.................................................. 2-12
2.5.9 Adsorber filling ........................................................... 2-13

H2-Production Plan HABAS Turkey 263100674/00, 722E002_uk, 28.03.20137 2-1/13

 Description of the H2-Plant

2.1 Use
This plant is conceived for derivation of hydrogen
from Natural Gas.
The design specifications of the plant as well as
its preset values correspond to the following
specifications :
• Input Natural Gas (at Battery Limit):
Temperature: 20,0 °C
3
Density: 0,79 kg/Nm
Pressure: 4,0 bar (g)
Flow (feed + fuel): 111 Nm3/h
Composition : CH4 90,8 Vol-%
C2H6 3,3 Vol-%
C3H8 1,2 Vol-%
i/n-C4H10 0,5 Vol-%
i/n-C5H12 0,1 Vol-%
CO2 0,5 Vol-%
O2 0,5 Vol-%
N2 3,4 Vol-%

Content of olefins/unsaturated hydrocarbons:

Max. 1 wt-%
Lower heating value is min. 8.320 kcal/kg
H2S: max. 5,1 mg/Nm3 natural gas
Mercaptane: max.15,3 mg/Nm3 natural gas
Total sulphur content: max. 110 mg/Nm3
Total sulphur content for design of
desulphurization reactor: max. 30 mg/Nm3 natural
gas for 1 year
• Output product gas:
Flow: 250,0 Nm3/h
Pressure: 12,0 bar (g)
Temperature (approx): 30-40 °C
3
Density: 0,09 kg/Nm
Composition : H2 99,999 Vol.-%
Impurities: CH4+CO+ CO2 < 1 ppm vol.

H2-Production Plan HABAS Turkey 263100674/00, 722E002_uk, 28.03.20137 2-2/13


2.2 System specification
⇒ see P+I diagrams 1-27-520949-0
Feed Pretreatment
⇒ see P+I diagram
1-27-520949-0 sheet 1
⇒ Steam reformer D13101
see P+I diagram
1-27-520949-0 Sheet 2
⇒ Feed preheater W14001
see P+I diagram
1-27-520949-0 Sheet 3
H2-Production Plan HABAS Turkey 263100674/00, 722E002_uk, 28.03.20137
Description of the H2-Plant
H2O < 2 ppm vol.
O2 < 2 ppm vol.
N2 < 5 ppm vol.
Natural Gas from battery limits (B.L.) at a pressure
between of 4 bar (abs) is divided in two streams.
One is used as fuel and sent to the reformer
burners in D13101. The other one is mixed with a
H2-recycle stream from the PSA-unit to the feed
gas and will be compressed by a watercooled
piston compressor to a pressure of 20 bar (g).
The feed + H2-recycle stream is warmed up to
approx. 390 C in the feed-preheater W14001 and
then fed in the desulphurization reactor C10201.
The reactor is filled with a catalyst composed of
zinc oxide, molybdenum oxide and copper oxide.
The following reactions take place:
• Unsaturated hydrocarbons are hydrogenated.
The temperature in the reactor rises pro-
portionally to the content of the unsaturated
hydrocarbons in the feed. The maximum
tolerable content of unsaturated compounds is
2%.
• Non-reactive sulphur compounds are hydro-
genated to hydrogen sulphide.
• The hydrogen sulphide is absorbed.
The zinc oxide bed is designed for a running time
of 8500 hours at 100% load with a total sulphur
content of 10 ppm/kg NG (each bed).
The zincoxide beds will also be able to cover 100
ppm wt. sulphur, but the livetime would be
shortened accordingly.
2-3/13

Reformer Furnace and HT-CO-Shift
⇒ D13101 see P+I diagram
1-27-520949-0 Sheet 2
⇒ D11001 and W11001 see
P+I diagram
1-27-520949-0 Sheet 2
⇒ D11001 and W11003 see
P+I diagram
1-27-520949-0 Sheet 2
⇒ C14001 see P+I diagram
1-27-520949-0 Sheet 3
Heat Recovery from the Converted Process Gas
⇒ W14001 ,W14002 and
see P+I diagram
1-27-520949-0 Sheet 3
H2-Production Plan HABAS Turkey 263100674/00, 722E002_uk, 28.03.20137
Description of the H2-Plant
The desulphurized feed is then mixed with
process steam from waste gas boiler D11001,
warmed up to approx. 490°C in super heater
W11001 and passed into the steam reforming
furnace D13101.
The reforming of the feed/steam mixture takes
place in the heated high-alloy reformer tubes
which are filled with a nickel-based catalyst.
Basically the following reactions take place:
CnHm+n H2O = (n+m/2)H2+n CO (endothermic)
CO+H2O = CO2+H2 (exothermic).
The total heat balance is endothermic. The hot
reformed gas leaves the tubes at approx. 840°C.
The gas is then cooled down in the reformed gas
cooler W11003 to approx. 350°C by generation of
saturated steam at approx. 23 bar(abs). The
cooler W11003 is integrated in the waste gas
boiler D11001. The correct outlet temperature of
the reformed gas is controlled by an internal
bypass to ensure optimal operating conditions
also in part-load.
The reformed gas is passed through the high-
temperature-CO-shift converter C14001. The
converter contains an iron oxide / chromium oxide
catalyst. Most of the carbon monoxide reacts with
the excess steam present in the reformed gas to
produce additional hydrogen and carbon dioxide:
CO+H2O = CO2+H2.
The reaction is exothermic and the converted gas
leaves the reactor C14001 at approx. 410°C.
The heat of the converted gas is recovered in the
following series of heat exchangers:
• In the first heat exchanger (feed preheater
W14001) the heat of the converted gas is
recovered by warming up the feed + H2-recycle
stream to approx. 300°C.
• The second heat exchanger W14002 is used
as economizer where the degasified boiler feed
2-4/13

⇒ W14003 see P+I diagram
1-27-520949-0 Sheet 4
⇒ F14001 see P+I diagram
1-27-520949-0 Sheet 4
Pressure-Swing-Adsorption System
⇒ PSA see P+I diagram
1-27-520949-0 Sheet 5
H2-Production Plan HABAS Turkey 263100674/00, 722E002_uk, 28.03.20137
Description of the H2-Plant
water (bfw) is warmed up by recovered heat
from 100°C to approx. 220°C.
• The final cooling-down of the converted gas to
approx. 35 - 45 °C is conducted in the water
cooler W14003.
During the cooling-down process the excess
steam in the converted gas is condensed and
separated in process knock-out drum F14001.
The process condensate will be recycled during
normal operation or sent to the sewer system
respectively to the Battery Limits.
The converted gas enters the PSA-system
A14101–A14104.
In the PSA-system the hydrogen is separated
from the impurities, eg. H2O, CO, CO2, N2 and
CH4.
The PSA-system consists of 4 Adsorber A14101–
A14104, each filled with 3 types of adsorbents.
The impurities are adsorbed at product pressure.
The regeneration of the adsorbents takes place by
depressurization to low pressure and purging.
A complete cycle consists of the following steps:
Adsorption: During the adsorption step, the
process gas enters the bottom of the Adsorber.
The impurities are adsorbed and the high pure H2
leaves the Adsorber on top. The pressure in the
PSA-unit is kept at a constant level by a pressure
control valve in the H2-line. When the adsorption
step is finished, automatically a regenerated
Adsorber is switched on adsorption, thus a
continuous product flow is achieved.
Regeneration: The regeneration of the exhausted
Adsorber starts by depressurization to a low
pressure level. During this step most of the gas is
used for depressurization and purging of other
Adsorber, which are in different stages of
regeneration. The final depressurization gas is fed
in the purge gas vessel B14201.
Purging: The pressure in the Adsorber is about
ambient pressure. The Adsorber is purged with
2-5/13

⇒ B14201 see P+I diagram
1-27-520949-0 Sheet 5
⇒ D13101 see P+I diagram
1-27-520949-0 Sheet 2
H2-Production Plan HABAS Turkey 263100674/00, 722E002_uk, 28.03.20137
Description of the H2-Plant
hydrogen-rich gas from another Adsorber. The
purge gas is sent to the purge gas vessel B14201.
Depressurization: The pressure in the purged
Adsorber is increased up to adsorption pressure.
This is done by depressurization gas coming from
other Adsorber and finally by a recycle stream of
H2-product. The Adsorber is now regenerated and
will be switched over for adsorption.
At any given time of the cycle, one Adsorber of the
4-bed system is adsorbing the impurities, while
the others are in various stages of regeneration.
The optimum control of the PSA-system is done
by a programmable computerized logic control
system (PLC), which allows a high efficiency of
the PSA-system. This system adapts auto-
matically the cycle time of the process, thus for all
part-loads an optimum H2-recovery is achieved.
The H2-product is sent to battery limits at a
pressure of 15,0 bar (abs) and sent to a H2-buffer
of Habas (not in the scope of supply) and than to
3 pc Hydrogen Compressors (each capacity is
2500 Nm3/h and 43 bar (g)).
A small H2-stream will be recycled and mixed with
feed for the hydrogenation and desulphurization of
the natural gas.
The purge gas from the PSA-unit contains the
impurities H2O, CO2, CO, N2, CH4 and some H2.
The purge gas is fed in the buffer vessel B14201,
which is designed for a certain hold-up to
minimize fluctuation in purge gas concentration,
heating value and Wobble. The purge gas is
returned to the reformer and used as fuel. During
normal operation approx. 90 % of the required
heat in the furnace D13101 is supplied by this
purge gas. The additional required heat is
generated by burning of natural gas (fuel) coming
from battery limits.
During start-up of the plant, the pressure profile is
adjusted by the bypass solenoid valves at the
Adsorber inlet. If the pressure swing adsorption
plant stops, but can be started and operated later
on in the same sequence as before the stoppage,
it is not necessary to adjust the pressure profile
anew.
2-6/13

Boiler Feed Water (BFW)-System
⇒ B12101 see P+I diagram
1-27-520949-0 Sheet 4
⇒ P12001/2 and P12003/4
see P+I diagram
1-27-520949-0 Sheet 4
Waste gas-Heat Recovery System
⇒ D13101 see P+I diagram
1-27-520949-0 Sheet 2
⇒ D11001 see P+I diagram
1-27-520949-0 Sheet 2
⇒ W11001, W11002 and
W11003 see P+I diagram
1-27-520949-0 Sheet 2
⇒ V11001 and AA11001 see
P+I diagram
1-27-520949-0 Sheet 2
H2-Production Plan HABAS Turkey 263100674/00, 722E002_uk, 28.03.20137
Description of the H2-Plant
The demineralized water from battery limits is
warmed-up in the BFW-preheater W14003 from
approx. 20°C to approx. 100°C. The BFW is
degasified in the deaerator B12101, dosed with
water treatment chemicals (phosphate and
sulfite).
The BFW-pumps P12001/2 and P12003/4 1)
increase the pressure to approx. 29 bar (abs). The
BFW is warmed up to approx. 210°C in the
economizer W14002 before it is fed into the waste
gas boiler D11001.
The heat of the hot waste gas leaving the
reformer D13101 is recovered in the following
way:
• Preheating of feed and process steam in the
super heater W11001 to approx. 490°C.
• Generation of process steam in the waste gas
boiler D11001. The process steam is mixed
with the desulphurized feed and routed to
W11001.
• Preheating of combustion air from approx. 20°C
to approx. 390°C in combustion air preheater
W11002.
The reformed gas cooler W11003 is also
integrated in the waste gas boiler D11001. The
correct outlet temperature of the reformed gas is
controlled by an internal bypass to ensure optimal
operating conditions also in part-load.
The waste gas leaves the plant via waste gas fan
V11001 and stack AA11001.
2-7/13
 Description of the H2-Plant

2.3 Appropriate use

• The plant specified here has been designed
for H2-production from Natural Gas.
⇒ see 2.2 “System specification“, page 2-3
Any other use is regarded as inadmissible. The
manufacturer is not liable for the unauthorized
operation of the plant and any damage this might
cause.
The plant may only be operated by qualified
personnel.
Any modification to the plant is strictly prohibited.
Such unauthorized modification discharges
Mahler AGS entirely of liability.
Mahler AGS is in no way liable for hazards which
may arise from handling the gases produced by
the operation of the plant.

H2-Production Plan HABAS Turkey 263100674/00, 722E002_uk, 28.03.20137 2-8/13

 Description of the H2-Plant

2.4 Technical data

System H2-plant
Type steam reforming
Manufacturer Mahler AGS
Customer HABAS
Izmit / Turkey
Constructed in Year 2012
3
Nominal capacity 250 Nm /h

Plant dimensions:
Width 31200 mm
Depth 30000 mm
Height approx. 26000 mm
Load, see Foundation diagram
1-19-519-484-0

Input:
3
Natural Gas Flow 111 Nm /h
Temperature 20 °C
Pressure 4 bar (g)
3
Density 0,79 kg/m

3
Nitrogen Flow 60…80 Nm /h
Purity: 99,99 Vol-% Temperature 20 °C
Pressure 6 / min. 4 bar (g)
3
Density 1,250 kg/m

3
Instrument air Flow 15 Nm /h
Temperature Amb. °C
Pressure 5-7 bar (g)

3
Cooling water Flow 11 m /h
Temperature 27-30 °C
Pressure 4-5 bar (g)

Demineralized water Flow 320 kg/h

Temperature 20 °C
Pressure 3 bar (g)

H2-Production Plan HABAS Turkey 263100674/00, 722E002_uk, 28.03.20137 2-9/13

 Description of the H2-Plant

Outlet:

3
Product gas Flow 250 Nm /h
Pressure 12 bar (g)
Temperature 30-40 °C
3
Density 0,090 kg/Nm

Electrical connections: (Rated Power)

Waste Gas Blower Motor M11001 15,0 kW
Boiler feed water pump motor 1,1 kW
M12001
Boiler feed water pump motor 4,0 kW
M12002
Boiler feed water pump motor 1,1 kW
M12003
Boiler feed water pump motor 4,0 kW
M12004
Dosing unit P12105/7 0,03 kW
Combustion air blower motor M1601 11,0 kW
Central air blower motor M1602 2,2 kW
Natural Gas Compressor M10101 10,0 kW

Power required
Voltage 3x380 VAC
N/PE
Frequency 50 Hz
Installed Power 78 KW

+ Further technical specifications ⇑ are enclosed in

“Operation manuals of sub suppliers”

H2-Production Plan HABAS Turkey 263100674/00, 722E002_uk, 28.03.20137 2-10/13

 Description of the H2-Plant

2.5 Specification of operating media

2.5.1 Natural Gas (only design)

Methan (CH4) 90,8 Vol. %
Ethane (C2H6) 3,3 Vol. %
Propane (C3H8) 1,2 Vol.-%
n-Butane (C4H10) 0,5 Vol.-%
n-Pentane (C5H12) 0,1 Vol.-%
Hexane (C6H14) 0,04 Vol.-%
Oxygen 0,03 Vol.-%
Nitrogen 3,4 Vol-%
Carbon doixide 0,47 Vol-%
Pressure 4 bar(g)
Temperature 20 °C
Flow 111 kg/h

2.5.2 Nitrogen
3
Flow 60 – 80 Nm /h
Temperature 20 °C
Pressure min. 4 bar (g)
3
Density 1,250 kg/m

2.5.3 Instrument air

Quality dry, free of oil and grease,
free of mechanical
impurities
Flow 10-20 Nm3/h
Pressure 5-6 bar (g)
Temperature Amb. °C
Dew point -40 °C

H2-Production Plan HABAS Turkey 263100674/00, 722E002_uk, 28.03.20137 2-11/13

 Description of the H2-Plant

2.5.4 Cooling water

Quality clean ,non-corrosive; no saltwater
3
Flow 11 m /h
Pressure 4,0 bar(g)
Temperature 30-34 °C

2.5.5 Demineralized water

Quality clean, non-corrosive; no saltwater
Mass flow 320 Kg/h
Pressure 3 bar(g)
Temperature 20 °C

2.5.6 Desulphurization catalyst

Filling catalyst K4
Quantity 260 liter
Service life 1 year

2.5.7 Reformer catalyst

Filling catalyst K6
Quantity 77 liter/tube
Service life 4 years
The plant is designed with 3 reformer tubes.

2.5.8 HT-CO-reactor filling

Filling catalyst A15
Quantity 182 liter
Service life 4 years

Filling ceramic balls, diameter ½”

Quantity 2 x 40 liter
Service life 4 years

H2-Production Plan HABAS Turkey 263100674/00, 722E002_uk, 28.03.20137 2-12/13

 Description of the H2-Plant

2.5.9 Adsorber filling

Filling aluminum oxide
Quantity 151 kg/Adsorber
Service life >10 years

Filling active carbon

Quantity 320 kg/Adsorber
Service life >10 years

Filling molecular sieve

Quantity 420 kg/Adsorber
Service life >10 years
The plant is designed with 4 Adsorber.

H2-Production Plan HABAS Turkey 263100674/00, 722E002_uk, 28.03.20137 2-13/13