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The Power of Experience Final Report Hydrogen Delivery Infrastructure Options Analysis DOE Award Number: DE-FG36-05GO15032 Project director/principal investigator: Tan-Ping Chen Consortium/teaming Partners: Air Liquide, Chevron Technology Venture, Gas Technology Institute, NREL, Tiax, ANL TABLE OF CONTENTS SECTION 1 EXECUTIVE SUMMARY ........................................................................... 1-1 1.1 HOW THE RESEARCH ADDS TO THE UNDERSTANDING OF THE AREA INVESTIGATED.1-1 1.2 TECHNICAL EFFECTIVENESS AND ECONOMIC FEASIBILITY OF THE METHODS OR TECHNIQUES INVESTIGATED OR DEMONSTRATED .................................................... 1-1 1.3 HOW THE PROJECT IS OF BENEFIT TO THE PUBLIC..................................................... 1-1 SECTION 2 COMPARISON OF ACTUAL ACCOMPLISHMENTS WITH PROJECT GOALS.................................................................................................................................. 2-1 2.1 TASK 1: COLLECT AND COMPILE DATA AND KNOWLEDGE BASE ........................... 2-2 2.2 TASK 2: EVALUATE CURRENT AND FUTURE EFFICIENCIES AND COSTS OF HYDROGEN DELIVERY OPTIONS ................................................................................................ 2-5 2.3 TASK 3: EVALUATE EXISTING INFRASTRUCTURE CAPABILITY FOR HYDROGEN DELIVERY ............................................................................................................... 2-6 2.4 TASK 4: ASSESS GHG AND POLLUTANT EMISSIONS IN HYDROGEN DELIVERY....... 2-7 2.5 TASK 5: COMPARE AND RANK DELIVERY OPTIONS INCLUDING THE USE OF COST MODELS .................................................................................................................. 2-7 2.6 TASK 6: RECOMMEND HYDROGEN DELIVERY STRATEGIES .................................... 2-7 2.7 TASK 7: PROJECT MANAGEMENT AND REPORTING ................................................. 2-7 SECTION 3 SUMMARY OF PROJECT ACTIVITIES ................................................. 3-1 SECTION 4 PRODUCTS DEVELOPED AND TECHNOLOGY TRANSFER ACTIVITIES........................................................................................................................ 4-2 APPENDIX A TASK 1 REPORT ..........................................................................................1 APPENDIX B TASK 2 REPORT..........................................................................................2 APPENDIX C SUPPLEMENTAL REPORT TO TASK 2 FOR NOVEL CARRIER ANALYSIS ...............................................................................................................................3 Hydrogen Delivery Infrastructure Options Analysis ii Section 1 Executive Summary 1.1 HOW THE RESEARCH ADDS TO THE UNDERSTANDING OF THE AREA INVESTIGATED In the long run, central hydrogen production is a less costly option than the on-site production at point of use due to the economy of scale for the larger central production facilities. This project provides an in-depth analysis to determine the cost effective mechanism for the transport and delivery of hydrogen from the central production facilities to the point of use at a refueling station. 1.2 TECHNICAL EFFECTIVENESS AND ECONOMIC FEASIBILITY OF THE METHODS OR TECHNIQUES INVESTIGATED OR DEMONSTRATED The investigation involved only paper study and had no laboratory or pilot scale testing. There are no special techniques used in the investigations. 1.3 HOW THE PROJECT IS OF BENEFIT TO THE PUBLIC The project benefits the public in determining the effective roadmap to build hydrogen economy for providing carbon-free fuels in transportation sector. Hydrogen Delivery Infrastructure Options Analysis 1-1 Section 2 Comparison of Actual Accomplishments with Project Goals In this project, the Nexant team conducted an in-depth analysis of various hydrogen delivery options to provide basis for determining the most cost effective infrastructure for the transition and long term. The major objective of the project is to assist DOE to understand hydrogen delivery options and plan required R&D efforts. The project evaluated and analyzed the following seven hydrogen delivery options: Option 1: Dedicated pipelines for gaseous hydrogen delivery Option 2: Use of existing natural gas or oil pipelines for gaseous hydrogen delivery Option 3: Use of existing natural gas pipelines by blending in gaseous hydrogen with the separation of hydrogen from natural gas at the point of use Option 4: Truck or rail delivery of gaseous hydrogen Option 5: Truck, rail, or pipeline transport of liquid hydrogen Option 6: Use of novel solid or liquid H2 carriers in slurry/solvent form transported by pipeline/rail/trucks Option 7: Transport methanol or ethanol by truck, rail, or pipeline and reform it into hydrogen at point of use Delivery includes the entire infrastructure needed to transport, store, and deliver hydrogen from the point of production at 300 psi (central, semi-central, or distributed) to the point of use at the dispensing nozzle at a refueling station or stationary power site. The Nexant team conducted the analysis in seven tasks: Task 1: Collect and Compile Data and Knowledge Base Subtask 1.1: Pipeline/truck/rail GH delivery and truck/rail LH delivery Subtask 1.2: Natural gas pipelines Subtask 1.3: Novel solid/liquid H2 carrier processes Subtask 1.4: H2/natural gas separation processes Subtask 1.5: H2/carrier storage needs and technology for delivery infrastructure Subtask 1.6: Methanol/ethanol production, transport & conversion Subtask 1.7: Previous system analysis and modeling work completed Task 2: Evaluate Current and Future Efficiencies and Costs of Hydrogen Delivery Options Subtask 2.1: Establish Analysis Bases Subtask 2.2: Conduct Conceptual Design Subtask 2.3: Cost Estimate and Financial Analysis Task 3: Evaluate Existing Infrastructure Capability for Hydrogen Delivery Task 4: Assess GHG and Pollutant Emissions in Hydrogen Delivery Task 5: Compare and Rank Delivery Options including the use of cost models Hydrogen Delivery Infrastructure Options Analysis 2-1 Task 6: Recommend Hydrogen Delivery Strategies Task 7: Project Management and Reporting A comparison of actual accomplishments in these seven tasks with the project goals is provided below. 2.1 TASK 1: COLLECT AND COMPILE DATA AND KNOWLEDGE BASE Project Goal In Task 1, the goal is for the Nexant team to collect and compile the relevant data and knowledge base for each delivery option to facilitate the analyses in Tasks 2-6. Task 1 consists of the following seven subtasks: Subtask 1.1: Pipeline/truck/rail GH delivery and truck/rail LH delivery For the GH delivery by pipelines, the Nexant team will: Collect information on the existing hydrogen gas pipelines in US Summarize experiences in the construction, operation, and maintenance of hydrogen gas pipelines in US and other parts of world Identify issues related to the use of hydrogen gas pipelines Survey the new technologies, which might have impacts on the efficiency, cost, and reliability improvements of hydrogen pipelines, including the key players, development status, and the projected progress as a function of time For the truck and rail transport of GH and LH, the Nexant team will: Collect information on the current GH and LH delivery by trucks and rails from merchant hydrogen plants in US Identify issues related to these transport modes Survey the new technologies, which might have impacts on the efficiency, cost, and reliability improvements of GH and LH truck/rail deliveries, including the key players, development status, and the projected progress as a function of time The information collected and compiled will be used as the basis to design and estimate the current and future capital and O&M costs of hydrogen pipeline transport in Task 2, to provide the necessary input to evaluate the existing infrastructure for hydrogen transport in Task 3, and form the basis to assess the GHG/pollutant emissions in Task 4. Subtask 1.2: Natural gas pipelines In this subtask, the Nexant team will: Collect information on the existing natural gas pipeline network (transmission and trunk lines) in US in terms of where the transmission and trunk lines are, flow rates, line sizes, delivery pressures, transport distances, locations of the feed and boost compression stations, construction materials, capital costs, compression energy Hydrogen Delivery Infrastructure Options Analysis 2-2 consumptions, emissions from the compression stations, leakages and losses, maintenance requirements, and other O&M expenses. Collect information on the capital cost and O&M costs of the distribution system in US Assess the ability of the current transmission and distribution network to isolate a certain portion of the system to transport hydrogen without interfering the natural gas transport The information collected and compiled will be used as the basis to design and cost estimate the retrofit of current NG pipeline to transport hydrogen or mixture of natural gas/hydrogen in Task 2 and provide the necessary input to evaluate the existing infrastructure capability for hydrogen delivery in Task 3. Subtask 1.3: Novel solid/liquid H2 carrier processes In this subtask, Tiax will survey and screen novel processes using solid/liquid hydrogen carriers. It will cover the following four classes of processes: Reversible processes in using metal hydrides (such as LaNi5 and Mg2Ni) and alanates (such as NaAlH4) Irreversible processes in using chemical hydrides, such as LiH, NaH, and sodium borohydride Advanced reversible processes utilizing
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