Phase 1 SBRI Hydrogen Supply Competition

Bulk Hydrogen Production by

Sorbent Enhanced Steam Reforming
(HyPER) Project

Cranfield University
The Gas Technology Institute
Doosan Babcock

TRN 2039/09/2019
Executive Summary
Low carbon hydrogen (H2) will play an important role for decarbonising industry,
power, heat and transport. The Royal Society concluded that steam methane
reforming with some form of carbon capture and utilisation/storage (CCUS) was one
of the most likely technologies to be deployed at scale in the near to mid-term. We
propose to answer the call for technology development leading to a low carbon bulk
H2 supply through pilot scale demonstration of the sorption enhanced steam
reforming process, based on an existing GTI technology.

The Phase 1 feasibility study confirmed the opportunity for the GTI sorption
enhanced steam reforming process to offer bulk low carbon H2 production with over
50% CAPEX reduction and up to 98% carbon capture through integrated CO2
separation. With the potential to develop zero carbon H2 reforming as part of scale
up, this technology could significantly accelerate affordable decarbonisation of heat,
power and transport. For Phase 2, we propose a pilot scale demonstration using our
existing expertise to take this technology from TRL 4 to 6, demonstrating the process
as a full-chain integrated system for commercial industrial deployment.

Application of the H2 production technology demonstrated in the HyPER project, and

deployed in industrial clusters, offers accelerated and affordable decarbonisation to
meet the UK net zero 2050 target.

HyPER Project Page | 1

Table of Contents
Executive Summary .............................................................................................................. 1

1. Introduction to H2 and Phase 1 of the HyPER Project .................................................... 3

2. Summary of Phase 1 activities and outcomes ................................................................ 4

2.1 H2 market assessment ............................................................................................ 4

2.2 Process modelling................................................................................................... 5

2.3 Techno-economics of the CHG process.................................................................. 7

2.4 HyPER pilot plant design ........................................................................................ 9

3. Overall achievements of Phase 1 and short-term development plan ............................ 11

4. Description of Phase 2 ................................................................................................. 13

5. Economic benefit to HM Government of Phase 1 and 2 ............................................... 16

6. Beyond Phase 2........................................................................................................... 17

7. References .................................................................................................................. 18

8. Appendices .................................................................................................................. 19

8.1 Aspen process flow sheeting model ...................................................................... 19

8.2 Process flow diagram (PFD) ................................................................................. 20

HyPER Project Page | 2

1. Introduction to H2 and Phase 1 of the HyPER Project
Hydrogen (H2) is already globally utilised at a scale of approx. 55M Tonnes every year,
where it is used to make ammonia, methanol, and other chemicals in addition to being
widely used in oil refineries. With the global ambition of decarbonising every aspect of
society we must revolutionise the technologies and processes that we currently use, for
which H2 can play an important role, for example in decarbonising heating systems, vehicles,
energy storage, power production, and energy-intensive industries. However, it is imperative
that the use of H2 in these sources is ‘clean’ – i.e. zero or minimal CO2 emissions produced
during the H2 production step.

Steam Methane Reforming (SMR) technology is the predominate technology used in the
production of bulk H2, but it emits 8-12 kg of CO2 for every kg of H2 produced. Although
conventional SMR has been extensively studied for H2 production. Decarbonising it entails
installing a separate carbon capture unit downstream of the facility to comply with the next-
generation carbon emission targets.

This Phase 1 project explored the feasibility of producing bulk quantities of H2 from the
sorption enhanced steam methane reforming process integrated with an indirectly heated
calciner to facilitate the separation and removal of CO2 from the system in a solid phase.
This has been extensively developed in the US by the Gas Technology Institute (GTI). The
Compact H2 Generator (CHG) Technology patented by GTI can reduce the LCOH up to 20%
and CAPEX over 50% compared with SMR technology with 98% carbon capture.

HyPER Project Page | 3

2. Summary of Phase 1 activities and outcomes
2.1 H2 market assessment
The market study considered the potential geographical market opportunities and different
conflicting parameters for the adoption of the proposed CHG technology. Countries with high
natural gas consumption/export were addressed initially since the CHG technology requires
natural gas use. Countries with carbon capture and storage programmes or those affiliated
with CO2 pipeline networks were also promising candidates for rapid take-up and
commercialisation. Furthermore, the suitability of several smaller “off-the-grid” industry
applications were also investigated because of the suitability of the CHG technology for such
installations.

Figure 1. Hydrogen deployment and scale up pathway.1

H2 itself is a carbon-free fuel and will play a key role in the energy mix for countries with
established CO2 reduction schemes. For instance, western European countries have already
forecast an increase in H2 demand from vehicles of all sizes, rail networks, heating, fuel and
chemical production and power generation (see Figure 1 for an example of the H2
deployment and scale up pathways suggested by the Hydrogen Council 1). Many countries
continue to rely heavily on natural gas to secure their energy supply and account for
variations in electricity generation caused by weather, seasonality, and the intermittent
generation profile of renewables. This continued use of natural gas is often seen as
conflicting with greenhouse gas emission reduction goals and thus H2 is being explored as a
clean energy vector that can be stored, transported and used in similar manners to natural

HyPER Project Page | 4

gas. Our study highlighted that countries with a high penetration of renewables would still opt
for gas-to-power technologies, using natural gas to produce H2, as it is able to balance
supply and demand, and has minimal visual impact on the environment and is therefore
more socially acceptable.

The adoption of the proposed CHG H2 production technology does require functional and
available CO2 storage to be considered a low carbon option. Therefore, those countries
investigating and implementing CO2 capture with use, geo-storage or export are key target
markets. Some countries have identified market opportunities for H2 export and have put in
place financial incentives towards this goal and H2's overall use at different scales.

The growth of the CHG technology will be linked with the expanding H2 market, greenhouse
gas emissions legislation, and the development of key infrastructure (i.e. gas grid).
Therefore, near-term applications of the proposed CHG technology will be focussed on
industrial clusters where multiple potential uses of H2 exist. The CHG technology has the
capacity to scale up and expand into new markets as commitment to act on emissions
legislation increases. At the current market maturity level, the CHG technology represents a
prime candidate in the field of H2 production.

2.2 Process modelling

The process modelling activities were focussed on chemical equilibrium calculations and
optimisation of the system to maximise the CO2 capture rate, H2 yield, and overall thermal
efficiency. The process modelling was performed using Aspen Plus software. The reformer
equilibrium was modelled with data from HSC equilibrium software, which is based on Gibbs
energy minimisation. The modelling was performed for two different plant sizes:
1) 300 MWth counterfactual for benchmarking and demonstration of the potential of
the CHG at full-scale, once commercialised
2) 1.5 MWth pilot plant as the concept for Phase 2 of this competition

The counterfactual plant layout was simplified by excluding without thermal integration for
comparison at the pilot scale. Modelling of the CHG concept was performed to demonstrate
high pressure operation (4-30 bara) of the technology together with a closed sorbent loop.
This approach also facilitated flexible system control during the demonstration of the critical
components prior to whole plant testing.

A detailed description of the Pilot design is provided in section 2.4, but the overall CHG is
based on the sorption enhanced steam reforming process. This process is a second
generation hydrogen production process but offers a simpler process layout compared to the

HyPER Project Page | 5

counterfactual. There are two main reactors in this process, 1. a reformer/carbonator which
in the CHG is a fluidised bed reactor, 2. a calciner utilising an entrained flow reactor. Within
the reformer/carbonator the methane in natural gas is steam reformed into an impure
mixture of H2 and CO, the CO is then converted into CO2 by the water gas shift reaction and
in doing so produces more H2. The CO2 is captured with a sorbent and removed from the
gas stream thus leaving a relatively pure stream of H2 that can be further purified by a
Pressure Swing Adsorber. The captured CO2 is released in the calciner thus the overall
process generates two final gas streams, one of high purity H2 and one of high purity CO2,
the CO2 can then be transported, stored or used and is prevented from entering the
atmosphere and causing more climate change.

Figure 2. Performance of 1.5 MWth pilot plant with different PSAOG recycle rate.

Optimised process modelling demonstrated that the CHG was able to achieve CO2 capture
of >93% by recycling the Pressure Swing Adsorption Off Gas (PSAOG) into the process. An
overall layout of the modelling is available to view in Appendix 8.1. The methane conversion
at equilibrium changed as a function of steam to carbon ratio, temperature, and reactor
pressure. The amount of steam used as an input influenced the overall thermal efficiency of
the system therefore different process models were developed for different PSAOG recycle
fraction (see Figure 2). A recycle fraction of 75% was considered for the full-scale and pilot
plant models but this could be further increased if higher CO2 capture rates are required.
The H2 in the PSAOG recycle stream negatively affects the methane conversion by shifting
the reactor equilibrium and therefore the equilibrium process models were developed with
and without an additional membrane unit to scrub out the H2 before it was recycled. The

HyPER Project Page | 6

extent of carbon capture can be increased to nearly 98% through addition of this H2
membrane.

In order to finalise the preliminary design of the pilot plant, the minimum turn-down of the
process has been modelled considering the minimum superficial velocity requirement inside
the fluidised bed reactors. The process turn-down potential was found to be around 60%
which can be further extended by controlling the operating pressure or steam-to-methane
ratio. A set of process scale-up models were also developed for 50 MWth and 150 MWth
systems to estimate the impact on the Levelised Cost of Hydrogen (LCOH). Unlike the pilot
scale model that excludes thermal integration, the scale-up models considered this to
increase the overall thermal efficiency. The results indicate that the thermal performance of
50 MWth and 150 MWth systems are similar to that of the 300 MWth system.

2.3 Techno-economics of the CHG process

The original CHG process was optimised for the lowest LCOH production, but as a result
could not better the carbon capture rate of the Counterfactual at 90.1% 2. During the
feasibility study, the proposed process was reviewed, and a number of potential carbon
capture optimisation options were identified by the project team and confirmed through
extensive process modelling. As indicated in Section2.2, the recycling of the PSAOG
represented the most cost-effective means of increasing carbon capture. A further
improvement was made from the addition of a secondary H2 separation step, utilising a
commercially available H2 membrane technology. In addition to these process improvements
a transport calciner was proposed in place of an indirect-fired rotary kiln on account of
concerns over the effectiveness of heat transfer to the fine sorbent particles.

Despite the techno-economic benefits of operation at elevated pressure, the process has
thus far not been proven at the nominal design operating pressure of 24 bara. Therefore, the
lower-risk option of lower pressure operation was also considered.

The basis of the economic assessment of the CHG process was a bottom-up cost estimate
carried out for a 60 MSCFD (approximately 200 MWth) plant on the US Gulf Coast, delivering
99.99% H2 product purity and with the major equipment including materials, labour and
transport carried out in 2005.

A methodology was used to determine the Engineering, Procurement and Construction

(EPC) contract cost based on the bottom-up cost estimate with cognisance taken of the
construction, project contingency and EPC service costs utilised in the counterfactual EPC
contract cost. To ensure the selected approach was robust a baseline SMR costing carried

HyPER Project Page | 7

out in 2005 utilising the same methodology was treated similarly for comparison against
several references. The difference in costs was found to be a maximum of ±10%, well within
tolerances anticipated in an AACE Class IV estimate, and therefore determined to be fit for
purpose.

All costs are presented on a Q1 2017 basis and for cost escalation from 2005 price indices
from the Bureau of Labour Statistics for US industrial gas production 3
were utilised. For
variable operating costs, an electrical import was costed as appropriate to reflect
compressor duties, whilst the cost for storage of CO2 was assumed constant.

The performance and cost metrics of the optimised CHG high- and low-pressure options
versus the counterfactual Steam Methane Reforming plus post-combustion capture and
State of the Art (SOTA) - deemed to be Auto Thermal Reforming (ATR) plus Gas Heated
Reformer (GHR) 4
- are presented in Table 1. The counterfactual and SOTA were updated
according to 20 years lifetime and a discount rate of 10%.

Table 1. Techno-economic evaluation summary.

The CHG provides a clear advantage in carbon capture rate (up to 98%) and efficiency (up
to 73%) over the Counterfactual SMR+CCS and compares well with ATR+GHR. On a single
train basis, the economic analysis highlights that, for the high-pressure case, this advantage
is underwritten by a reduced capital expenditure (£105m vs £240m; a 56% reduction) and a
reduction in LCOH of 20% (£212/kNm3 to £170/kNm3). For the 4 bara scenario, the CAPEX
reduction is 53% and LCOH (£192/kNm3) is 10% lower than the Counterfactual.

The CAPEX and LCOH savings confirmed through Phase 1 activities highlight the dual
advantage of the CHG technology in terms of improved economics coupled with
HyPER Project Page | 8
performance. At 38.1 kgCO2/kNm3 the carbon footprint for the high pressure CHG case is
just 42% that of the Counterfactual. Operation at low pressure further reduces carbon
footprint to just 28.6 kgCO2/kNm3. The process also has the potential to reach near-zero
carbon emissions with 100% recycle.

2.4 HyPER pilot plant design

The proposed HyPER pilot plant is a 1.5 MWth pilot system of the CHG process, which
includes both the reforming and sorbent regeneration systems. The proposed system,
shown in Figure 3, enables detailed evaluation of the two key remaining risks of the system,
which are elevated pressure sorbent enhanced reforming in a bubbling fluidised bed and
reliable high-temperature solids handling. With the exception of process integration, the
substitution of multi-cyclones for filters and simulation of the recycle stream, all of the main
equipment expected of the full-scale plant is present on the pilot. The PSA, H2 membrane
separator and recycle gas compressors required for recycle at full scale represent
commercially available equipment having minimal technical or cost risk and, on that basis,
have not been considered for demonstration on the proposed pilot.

Figure 3. Proposed 1.5 MWth pilot system.

The proposed maximum output of 1.5 MWth represents an approximately 20x scale-up on
the existing 71 kWth facility in the US, achieved through a combination of increased physical
size and operating pressure. The 1.5 MWth pilot has been sized and a preliminary design of
the test article is shown in Figure 4.

HyPER Project Page | 9

 Figure 4. Proposed 1.5 MWth pilot test article configuration.

The intent of the proposed pilot facility is to demonstrate the continuous operation of the
CHG process at high pressure, producing a high yield of H2 product and high capture rate of
CO2. However, it is recognised that there are a number of risks attendant to accomplishing
this objective. Operation at lower pressure has been shown to be both technically (for
optimal H2 yield) and economically feasible, and therefore the achievement of this operating
point would also be considered a success, should any issues with operation at elevated
pressure arise. In addition, the lack of process integration specified (e.g. thermal integration)
on the pilot is intentional in order for the facility to remain flexible for the controlled proving of
components prior to whole system testing.

The preliminary engineering design carried out in the feasibility study included preliminary
engineering including Process Design and Safety, Piping, Mechanical, Electrical, Control
and Instrumentation, Layout, Civils and Construction activities with several preliminary
deliverables as follows:

• PFD (Appendix 8.2) • Valve and line list

• Heat and mass balance • Operating philosophy
• Preliminary P&ID • Plot plan
• Equipment list and specifications • HAZID/ENVID

These deliverables allowed for a clearer understanding of the technical barriers to scale-up
and plant reliability. All the engineering activities will be carried out in more detail in the next
Phase giving further understanding of any residual technical barriers and potential
mitigations following pilot demonstration.

HyPER Project Page | 10

3. Overall achievements of Phase 1 and short-term
development plan
The Phase 1 feasibility study confirmed that GTI’s CHG Technology with Integrated CO2
Capture can offer:

• The lowest cost H2 compared to the Counterfactual SMR + CCS by up to 20%

• Substantially lower CAPEX than Counterfactual by up to 56% with similar OPEX
• Equivalent H2 purity to Counterfactual while achieving up to 98% CO2 capture
• A significantly lower carbon footprint (<40% of the Counterfactual)

Full development of GTI’s CHG technology uses the ongoing small pilot-scale (0.071 MWth)
efforts at GTI in Chicago, US, in the Phase 2 demonstration (1.5 MWth) under the BEIS
Phase 2 Competition. The current work at GTI is funded with US-$6.5m (~£5.2m) by the
U.S. Department of Energy (DOE) with a further DOE feasibility study underway for a ~30
MWth H2-to-Power project. Figure 5 below shows the short-term development plan. The long-
term operation of the existing GTI small-scale pilot combined with the larger scale/ high-
pressure Phase 2 pilot operation will ensure that all major process risks will have been
reduced sufficiently to advance the technology to commercialisation.

Figure 5: Short-term development plan.

It is anticipated that the substantially lower CAPEX compared to conventional SMR

technology will be the key driver for a first commercial adopter, even without the requirement
for high CO2 capture rates. Initial business planning for such a project can start as early as

HyPER Project Page | 11

2021 with commercial operation before end of 2023 at an estimated cost of ~£12m for a 10
MWth design. The optimised 10 MWth design will then become the basis for larger 50 MWth
modules, benefitting from the compactness and low CAPEX of the CHG process, and
ultimately leading to 300 MWth and 1500 MWth systems.

In Phase 1, GTI, Doosan Babcock, and Cranfield University went through a structured
process to identify technical, environmental, economic, commercial, financial and project
management risks that need to be addressed. This provided a complementary assessment
to risks already identified and addressed under ongoing GTI activities. The primary technical
challenges relate to the operation of a steam methane reforming reaction in a fluidised bed
that includes a catalyst and a sorbent. The proposed pilot system will be able to operate at
higher pressure compared to the existing pilot at GTI.

For the short-term development, the key remaining commercial risks relate to 1. the total
equipment costs of the pilot, 2. the business arrangement between the parties and key
suppliers, 3. and identification of an early commercial opportunity.

1. Substantial efforts have been made to keep the cost of the pilot low while achieving
technical goals. e.g. rather than including a PSA for off gas recycle, that recycle
stream can be simulated through increased feed flow rate and dosing of impurities.
Lower cost construction materials will be used to account for the limited expected
operating life of the pilot and to accelerate the manufacture of the pilot.
2. The project partners have developed a teaming agreement that lays out their
business relationship.
3. For early market entry, small industrial applications (10 MWth) have been identified
with a number of possible first commercial projects at UK sites expected as part of
the BEIS grand challenge for Industrial Clusters.

HyPER Project Page | 12

4. Description of Phase 2
The purpose of Phase 2 is to validate the performance, operability and chemistry of the
HyPER system at a relevant scale and drive the HyPER technology towards
commercialisation. To achieve this purpose, a 1.5 MWth pilot will be designed, constructed
and commissioned at Cranfield University.

The detailed design will rely on the work completed in Phase 1 and results from the cold flow
validation testing of the transport calciner and the fluidised bed/freeboard tests. The
transport calciner cold flow testing will validate the particle velocity relative to the gas velocity
and verify the operability of the configuration currently envisioned. The fluidised
bed/freeboard cold flow testing will ensure the freeboard height is greater than the terminal
disengagement height of the spouting bed of catalyst particles. A HAZOP will be convened
upon completion of the updated Phase 2 Process Flow Diagram (PFD), definition of
operating conditions, and the Piping & Instrumentation Diagram (P&ID). The results from the
HAZOP will allow the design to be finalised and released for fabrication.

The site preparation will utilise the requirements from the PFD and the results of the HAZOP
to begin upgrading the facility to meet the testing requirements and to operate in a safe and
reliable manner. Details from the design will also be used to ensure adequacy of the existing
structure for supporting the test equipment. Instrumentation and control equipment will be
procured in line with the P&ID and equipment specifications that are compatible with the
data acquisition and control system. The existing control logic from GTI’s US pilot will be
used as the basis for the control programming.

Construction will occur in parallel with the site preparation. Equipment will be inspected and
cleared for installation in line with an assembly planning. Operating procedures will again
rely on GTI’s existing procedures for their basis. A Facility Requirements Review will be held
to ensure the Pilot is ready for commissioning for the first test campaign. Upon
commissioning, the first test campaign will commence.

The 1.5 MWth Pilot testing is divided into four campaigns which incrementally gather data
and complete the integrated Pilot. Test campaign 1, shown in Figure 6 and bordered by the
smallest dashed line, will validate the operation of the transport calciner, with the key
objectives of determining the heat balance of the calciner firebox and operational limits of the
calciner. The specific operating limit parameters are calcining temperature, calcination rate
and effect of steam concentration.

HyPER Project Page | 13

 Figure 6: HyPER 1.5 MWth Pilot test campaigns 1, 2, 3 and 4, layout and description.

Testing Campaign 2, shown in Figure 6 bordered by the medium dashed line, will
incorporate the pressurising lock hopper and H2 filter vessel into the system, with the key
purpose of validating operability of the pressurising lock hopper. The specific operability data
are the fill/drain cycle time, aeration rates, and stoppage resolution.

Testing campaign 3 (Figure 6, bordered by the solid line) will incorporate the bubbling
fluidised bed reactor and be the first campaign which generates H2. Figure 6 shows the
complete configuration, less the recycle simulant. This test series will incrementally grow the
output by starting at low pressure (4 bara) to demonstrate the functionality of the system.
The testing will incrementally increase the operating pressure once the performance data
and system reliability are achieved. The operating pressure will be increased to the following
pressures; 4 bara, 8 bara, 16 bara, and 24 bara. Other than overall proof of operation, this
campaign will enable refinement of the equilibrium models and fluidised bed reaction
kinetics- both of which are extremely valuable for future process modelling and system
optimisation.

Recycling the PSAOG is one of the novel features conceived during testing campaign 1 of
the overall project. To simulate the impact of the recycle the feed will be increased, and the
required contaminants will be injected from bottled storage. This test campaign (testing
campaign 4, shown on Figure 6 and boarded by the largest dashed line) will adequately

HyPER Project Page | 14

simulate the HyPER system concept and is where true validation of whole system
performance can be achieved. The results of the testing will be evaluated during the pilot
testing and will be used to refine the comparison against the counterfactual plant. The key
pieces of information are the validation of the system’s methane conversion, sorbent
reactivity, and calciner firebox efficiency. These three parameters drive the overall process
performance.

In conjunction with the HyPER 1.5 MWth Pilot testing, the commercialisation effort will
identify pathways for commercialisation and develop relationships with organisations
relevant to those pathways.

HyPER Project Page | 15

5. Economic benefit to HM Government of Phase 1 and 2
GTI’s CHG technology with integrated CO2 capture offers substantial advantages over a
conventional approach of H2 production with CO2 capture. Our Development Plan also
shows that with the CHG approach, large scale deployment of a low carbon H2 solution, i.e.
at a 1500 MWth scale, is feasible as early as 2030 and at lower cost than the Counterfactual
or any alternative solution that we are aware of. Acceleration of large scale, close to net-zero
H2 production through CHG could transform decarbonisation of heat and industry by more
than halving the capital cost compared with the Counterfactual.

Based on the LCOH analysis, the cost of H2 production at a 10 TWh/yr scale has been
calculated and is 20% lower than the counterfactual. The results demonstrate the excellent
value for money that the CHG technology offers. If the CHG technology was deployed at a
scale of 10 TWh/yr by 2035, in line with UK Government intentions, then the HM
Government could expect to see a £140m Return on Investment (RoI) in the 24 bara
scenario or £67m RoI in the 4 bara scenario, relative to the Counterfactual (SMR + CCS).
These calculations assume 8000 operational hours per year and are based on the lower
heating value of H2. These projections display the significant economic benefits that could be
realised in the UK economy each year over the lifetime of operation, thus providing jobs,
clean growth, and cheap and sustainable bulk H2 supply.

The ambitious development timeline is enabled by leveraging the substantial investment by

the U.S. Department of Energy (DOE), specifically the ongoing small-scale pilot work at GTI
which is funded by the DOE with US-$6.5m (~£5.2m). This funding is in addition to prior
cumulative investment by GTI (and predecessor Aerojet Rocketdyne) and DOE in excess of
$20m (~£16m). The DOE is also funding a Phase I feasibility study for a ~30 MWth H2-to-
Power project in the US. We anticipate that this study will result in a follow-on Phase 2 de-
risking effort at an estimated $3-4m (~£2.4-3.2m) investment focused on CHG-based H2-to-
Power. The design and engineering expertise, including proprietary design aspects, as well
as the operational experience gained in the US projects, will be directly utilised in the
proposed BEIS project. The projects have been designed such that there is no duplication of
technical or de-risking efforts and work cooperatively towards a common goal ensuring
maximum effectiveness in the use of funding.

HyPER Project Page | 16

6. Beyond Phase 2
Doosan Babcock with GTI and Cranfield University defined the long-term development plan
by building on the short-term development plan to not only achieve the proposed ‘stretching’
target for H2 supply above, but also define a product line scale up strategy to deliver state of
art scale, cost and performance significantly better than that achieved by the counterfactual.
Doosan Babcock has used its plant and process systems product design approach to define
the optimal path to large utility scale H2 production, considering the challenges associated
with reliability and performance that may emerge from the Phase 2 demonstration plant.

The extent of deployment required to support a H2 pathway to net zero in the UK by 2050
even by a progressive blending strategy, would need similar scale and investment in the
counterfactual technology to the build rate of utility scale H2 production plant in the UK’s H21
Max Scenario 4. We have used this UK market demand to define the route to market and
drive the timeline for scale up. The £130Bn H2 production plant CAPEX costs (2023-2050)
for H21 Max UK Rollout are extrapolated for current state-of-the-art (ATR) from the H21
North of England 12.15 GWth bulk H2 production facility cost of £8.5Bn. With this scale of
ambition in mind for alternative lower cost H2 production technologies like the CHG, the 10
TWh/yr by 2035 (equivalent to deployment of up to four counterfactual scale plants) would
require earlier achievement of 300 MWth scale for the CHG technology.

The long-term development plan not only achieves this but also considers how to deliver a
net zero carbon H2 solution. At an anticipated CO2 capture performance post Phase 2
optimisation approaching 98%, the consortium is confident that a viable net zero carbon H2
production CHG solution is achievable in the long-term development plan (by 2023). This
would turn state of art reforming/carbon capture from a transition technology into one that
unlocks affordable zero carbon H2 from methane to complement green H2 from electrolysis.

Our technology development roadmap and product roadmaps are targeting notice to
proceed (NTP) on the 300 MWth unit scale by 2025, deployable in modules for a 1500 MWth
CHG plant. This would not only achieve 10 TWh/yr scale production before 2030 but also
provide a viable alternative for possible selection in a UK net zero carbon H2 build
programme. The proposed development programme would look to consolidate the techno-
economic advantages over the counterfactual through learning by doing at each product
scale up stage, to realise the significant CAPEX and LCOH benefits (56% and 20%
respectively). To achieve the route to market, the technology development roadmap focuses
on delivering three principal low carbon H2 product lines; a 10 MWth small Industrial scale
CHG; a 50 MWth small Utility scale CHG; and a 300 MWth large utility scale CHG with an
initial twin train concept for the first 300 MWth plant (150 MWth each).
HyPER Project Page | 17
7. References
1. Hydrogen Council, 2017. Hydrogen - scaling up, a sustainable pathway for the global
energy transition. Available at: http://hydrogencouncil.com/wp-
content/uploads/2017/11/Hydrogen-scaling-up-Hydrogen-Council.pdf
2. R Ray and S Ferguson, 2018. Benchmarking State-of-the-art and Next Generation
Technologies, Wood report 13333-8820-RP-001 Rev 3A.
3. BLS Data Viewer, Accessed October 2019. United States Department of Labor.
Available at: https://beta.bls.gov/dataViewer/view/timeseries/PCU32512-32512-
;jsessionid=50C623B2B45382D0D986BB2CA783805B
4. D Sadler and H S Anderson, 2018. H21 North of England, Rev 1.

HyPER Project Page | 18

8. Appendices
8.1 Aspen process flow sheeting model

HyPER Project Page | 19

8.2 Process flow diagram (PFD)

HyPER Project Page | 20