CH4250 PROCESS ENGINEERING CAPSTONE PROJECT

BLUE HYDROGEN
Deliverable - 3
GROUP 17:

NAME ROLL NUMBER

GAGANDEEP CH21B037

AMARTYA TALUKDAR CH21B012

FAZAL CH21B097

NARENDRA KAWCHE CH21B065

MANISH AHIRWAR CH21B057

Product: Blue Hydrogen

Target: 5 MTPA
Location: Surat, Gujrat

1.​ INTRODUCTION

As the global energy landscape transitions towards cleaner alternatives, hydrogen is increasingly
recognized as a critical energy carrier. Within the various methods of hydrogen production, blue
hydrogen emerges as a significant low-carbon option, bridging the gap between hydrogen derived
from conventional fossil fuels and entirely renewable green hydrogen. Blue hydrogen originates from
natural gas through processes like reforming or oxidation, incorporating Carbon Capture and Storage
(CCS) technology to mitigate CO₂ emissions. This approach makes blue hydrogen a practical choice
for decarbonizing sectors with high hydrogen consumption, such as refining, chemical
manufacturing, steel production, and electricity generation.
 Compositions mol%

Methane 89

Ethane 7

Propane 1

Butane 0.1

Pentane 0.01

CO2 2

N2 0.89

2.​ MODELING SIMULATION

Table 1: Input Stream 1: Natural Gas

Temperature(°C) : 15
Pressure(bar): 1.25
​ ​
Lower heating value (MJ/kg) : 46.5

3.​ PROCESS DESCRIPTION

This simulation outlines a hydrogen production system based on partial oxidation. The model
incorporates the following key stages and components:
1.​ Feed System: Natural gas (or another hydrocarbon feed) is introduced into the process.
2.​ Partial Oxidation Reactor (B8): This is the central reactor where the oxidation reaction
occurs, producing synthesis gas (syngas) – a mixture containing H₂, CO, CO₂, and other
components.
3.​ Syngas Cooling & Separation: The hot syngas exiting the reactor is cooled through heat
exchangers (B6, B7) to manage its temperature before it enters separation units.
4.​ Compression & Purification: The cooled syngas is compressed (B1) and then fed into a
separation unit (B14). This unit isolates the hydrogen product from CO₂. The separated CO₂ is
typically vented or captured for utilization or storage.

3.1. OVERALL MASS BALANCE

The process adheres to the principle of mass conservation, described by the following balance
equations:
●​ Fundamental Equation: Total Mass In = Total Mass Out (ΣMass In = ΣMass Out)
●​ Input Streams:
○​ Methane (CH₄): X kg/h
○​ Oxygen (O₂): Y kg/h
○​ Water (H₂O) (potentially for shift reaction): W kg/h
●​ Output Streams (Products & Byproducts):
○​ Hydrogen (H₂): Z kg/h
○​ Carbon Monoxide (CO): A kg/h
○​ Carbon Dioxide (CO₂): B kg/h
○​ Unreacted components and purge streams are also accounted for.
●​ Governing Reactions for Mass Balance:
1.​ Partial Oxidation: CH₄ + 0.5O₂ → CO + 2H₂
2.​ Water-Gas Shift: CO + H₂O ⇌ CO₂ + H₂
●​ Total Mass Balance Equation: X + Y + W = Z + A + B + mass of other components
The final product composition is directly influenced by the conversion rate of methane and the
selectivity towards hydrogen production.

3.2 REACTION KINETICS

The reaction rates within the partial oxidation process are governed by the following key reactions
and kinetic parameters:

1. Primary Reaction: Partial Oxidation of Methane

●​ Equation: CH₄ + 0.5O₂ → CO + 2H₂ (Exothermic)
●​ Rate Equation: r_POX = k_POX * [CH₄]^a * [O₂]^b
○​ Where k_POX is the rate constant, and a/b are the reaction orders.
●​ Activation Energy (Ea): 120 kJ/mol

2. Secondary Reaction: Water-Gas Shift (WGS)

●​ Equation: CO + H₂O ⇌ CO₂ + H₂ (Exothermic)
●​ Rate Equation: r_WGS = k_WGS * ([CO][H₂O] - [CO₂][H₂]/K)
○​ Where K is the temperature-dependent equilibrium constant.
●​ Activation Energy (Ea): 85 kJ/mol

3. Kinetic Model Parameters:

●​ Reaction Orders: Typically assumed as first-order concerning CH₄ and O₂ for the primary
reaction.
●​ Temperature Dependence: The rate constants (k) follow the Arrhenius equation: k = A *
e^(-Ea/RT)
○​ A = Pre-exponential factor (1.5 × 10⁸ s⁻¹ for CH₄ oxidation; 1.2 × 10⁷ s⁻¹ for WGS reaction)
○​ Ea = Activation energy (J/mol, specified above for each reaction)
○​ R = Universal gas constant (8.314 J/mol·K)
○​ T = Absolute temperature (K)

3.3 EQUIPMENT: CONDITIONS AND MASS BALANCE

​ 3.3.1: Gasifier(B6)
Parameter Values

Design Pressure(barg) 25

Design Temperature(C) 200

Material Stainless Steel

Power(kW) 1500

Sizing Values

Vessel Diameter(meter) 1.8

Vessel Height(meter) 7.2

Liquid volume(L) 8000

Power(kW) 1500

Economics

Purchase Cost A1 $165800

Installation cost A2 $332000

CAPEX A1+A2 $497800

Fuel Cost B1 $160000 / year

Cooling water B2 $200 / year

Maintenance B3 $30,000/year

OPEX B1+B2+B3 $190,000/year

​ 3.3.2: Water gas shift(B12)
B11 & B12

Parameter Values

Design Pressure(barg) 25

Design Temperature(C) 200

Material Stainless Steel

Power(kW) 1500

Sizing Values

Vessel Diameter(meter) 1.8

Vessel Height(meter) 7.2

Liquid volume(L) 8000

Power(kW) 1500

Economics

Purchase Cost A1 $108800

Installation cost A2 $232000

CAPEX A1+A2 $340800

Fuel Cost B1 $160000 / year

Cooling water B2 $200 / year

Maintenance B3 $30,000/year

OPEX B1+B2+B3 $190,000/year

3.3.3: Reactor (RGibbs):

Parameter Values

Vessel Diameter(meter) 1.3716

Vessel Height(meter) 5.4864

Liquid volume(L) 8106.52

Temperature(C) 156.7781500

Design Pressure(barg) 23.65

Economics

Purchase Cost A1 $165800

Installation cost A2 $332000

CAPEX A1+A2 $497800

Fuel Cost B1 $160000 / year

Cooling water B2 $200 / year

Maintenance B3 $30,000/year

OPEX B1+B2+B3 $190,000/year

3.3.4 rGibbs(B8)

Parameter Values

Vessel Diameter(meter) 1.3716

Vessel Height(meter) 5.4864

Liquid volume(L) 8106.52

Temperature(C) 156.7781500

Pressure(barg) 22.4342

Economics

Column Cost A1 $360,000

Condenser Cost A2 $ 50,000

Reboiler Cost A3 $ 65,000

Installation Cost $ 237,500

CAPEX A1+A2 $712,500

Steam Cost B1 $87,600 / year

Cooling Water Costr B2 $8,760/ year

Maintenance Cost B3 $28,500/year

OPEX B1+B2+B3 $199,860/year

3.3.5 Adsorption column

CO2 adsorption on MDEA:

MDEA and SYNGAS is fed to the absorption tower (RAD-FRAC) column.

Economics

Purchase Cost A1 $165800

Installation cost A2 $332000

CAPEX A1+A2 $497800

Fuel Cost B1 $160000 / year

Cooling water B2 $200 / year

Maintenance B3 $30,000/year

OPEX B1+B2+B3 $190,000/year

Final Result (H2 purified) STREAM exiting Absorber:

We have formed 91% pure Blue -Hydrogen with a flow-rate of 5.34 kg/s

4.​ Safety Analysis (RAST)

We have done analysis for only B8 reactor.

We conducted a safety analysis for the Stirred Reactor / Crystallizer (BB) unit using RAST software
(v4.5), applying the Dow Fire & Explosion Index (F&EI) and Chemical Exposure Index (CEI)
methodologies.

The F&EI analysis yielded a Process Unit Hazard Factor (F3) of 1.75, primarily influenced by toxic
material properties and operating pressure. Based on the Material Factor (MF) for the Carbon Dioxide
Mix of [Insert MF Value], the resulting F&EI is [Insert Calculated F&EI Value]. This value signifies a
[Insert Hazard Category, e.g., Moderate, Severe] degree of fire and explosion hazard associated with
this unit.

The CEI analysis focused on potential releases of the Carbon Dioxide Mix (approx. 18,990 kg inventory,
vapor phase). The governing scenario identified was a large-bore pipe failure (613 mm), yielding a CEI
of 232. Crucially, the calculated hazard distances for this event (HD-2 = 2322 m based on ERPG-2;
HD-3 = 1942 m based on ERPG-3) extend well beyond the assumed 100 m distance to public areas,
indicating a potential for significant off-site consequences. A relief valve discharge scenario yielded a
lower CEI of 22 (HD-2 = 219 m).
 In summary, the RAST analysis highlights considerable fire, explosion, and toxic release risks for the
Stirred Reactor / Crystallizer unit, demanding robust safety measures, particularly concerning the
prevention of major containment loss.

●​ Economic Analysis:​

Overall CAPEX (Size to production): $497800 + $340800 + $497800 + $712,500 + $497800 =

$2,546,700 USD,

Overall OPEX: $190,000 + $190,000 + $190,000 + $199,860 + $190,000 (per year) =

$959,860 USD / Year

For Blue Hydrogen:​

Assumed Price Range: $2.00 - $2.50 USD per kg

Revenue (Low @ $2.0/kg) = 5,000,00 kg/year * $2.00/kg = $1,000,000 USD/Year

Calculate Annual Profit:

●​ Annual Profit = Annual Revenue - Total Annual OPEX

●​ Annual Profit (Low): $1,000,000 - $959,860 = $40140 USD/Year

Calculate Return on Investment (ROI):

●​ ROI (%) = (Annual Profit / Total CAPEX) * 100%

●​ ROI : ($40, 140 / $2,546,700) * 100% ≈ 1.58%

REFERENCES

●​ Turton, R., Shaeiwitz, J. A., Bhattacharyya, D., & Whiting, W. B. (2018). Analysis, Synthesis, and
Design of Chemical Processes (5th ed.). Prentice Hall. (Covers process design, simulation principles,
equipment sizing, and preliminary economics).
●​ Seider, W. D., Seader, J. D., Lewin, D. R., & Widagdo, S. (2016). Product and Process Design
Principles: Synthesis, Analysis, and Evaluation (4th ed.). Wiley. (Comprehensive text on process
design, simulation, and economics).
●​ Peters, M. S., Timmerhaus, K. D., & West, R. E. (2003). Plant Design and Economics for Chemical
Engineers (5th ed.). McGraw-Hill. (Classic text covering detailed cost estimation techniques for CAPEX
and OPEX).
●​ Garrett, D. E. (1989). Chemical Engineering Economics. Van Nostrand Reinhold. (Another resource for
cost estimation methods).
●​ Chemical Engineering Plant Cost Index (CEPCI): Published monthly in Chemical Engineering
Magazine. (Used for updating cost estimates to current dates – specify the index value and date used if
applied).
●​ RAST Software: Cite the specific version (e.g., RAST Version 4.5 as shown in your image) and its
source/provider if known (often associated with Dow or specific consulting groups implementing Dow's
methods).
●​ Center for Chemical Process Safety (CCPS). Guidelines for Hazard Evaluation Procedures (3rd ed.).
(2008). AIChE/Wiley. (Covers various hazard identification techniques like HAZOP).
●​ Mannan, S. (Ed.). (2012). Lees' Loss Prevention in the Process Industries (4th ed.).
Butterworth-Heinemann. (Comprehensive reference on process safety and loss prevention).