Feasibility study of a green hydrogen production plant for green ammonia

Annex 1 Equipment lists: Equipment list Main Equipment List Description Unit Quantity Cell Stack Skid PEM cell 20 Main Process Skid Deoxo reactor 2 Deoxo reactor feed heater 2 Regenerating gas electrical heater 2 Filter 4 Chilled water package 1 Cooling towers 1 Water purification package 1 DW polishing package 1 Power Module Electrical transformers 15 Vessel Description Tag number Quantity H2 separator H2&O2-VSL-1 20 O2 separator H2&O2-VSL-2 20 O2 demister H2&O2-VSL-3 20 H2 demister H2&O2-VSL-4 20 H2 flare Ko drum V-VSL-1 1 H2 deoxo reactor H2-VSL-1 1 H2 drier absorbent vessels H2-VSL-2 2 H2 direr cooler condensate pot H2-VSL-3 1 O2 deoxo reactor O2-VSL-1 1 O2 drier absorbent vessel O2-VSL-2 2 O2 direr cooler condensate pot O2-VSL-3 1 Liquid nitrogen storage and evaporator AN-VSL-1 1 Chilled water buffer tank CH-VSL-1 1 Tanks Description Tag number Quantity DI water tank DIW-TK-1 1 Resin tank DIW-TK-2 1 O2 drain tank H2&O2-TK-1 1 H2 drain tank H2&O2-TK-2 1 Effluents tank E-TK-1 1 Air nitrogen tank AN-TK-1 1 Cooling tower tank CT-TK-1 1 Heat Exchanger Description Tag number Quantity Heat exchanger CS-HX-1 1 Heat exchanger DIW-HX-1 1 O2 Heat exchanger H2&O2-HX-1 1 H2 Heat Exchanger H2&O2-HX-2 1 H2 dryer cooler shell and tube HX H2-HX-1 1 H2 dryer chiller shell and tube HX H2-HX-2 1 O2 dryer cooler shell and tube HX O2-HX-1 1 O2 dryer chiller shell and tube HX O2-HX-2 1 N2 aftercooler shell and tube HX AN-HX-1 1 Shell and tube heat exchanger AN-HX-2 1 O2 aftercooler shell and tube HX CP-HX-1 1 Rotating Equipment Description Tag Number Quantity Type DI circulation pump CS-PMP-1 1 Pump Polishing pump DIW-PMP-1 1 Pump Feed pump DIW-PMP-2 2 Pump H2 regenerating gas circulation pump H2-PMP-1 1 Pump O2 regenerating gas circulation pump O2-PMP-1 1 Pump Circulation pump E-PMP-1 1 Pump Effluents pit pump E-PMP-2 1 Pump Nitrogen compressor AN-COMP-1 1 Compressor Chilled water pump CH-PMP-1 1 Pump Oxygen compressor CP-COMP-1 1 Compressor Cooling water pumps CT-PMP-1 2 Pump Circulation pump DM-PMP-1 1 Pump Annex 2 Fluid list: ID. Description From To Basic pipe material CS-L1 DI WATER H2&O2 system; O2 separator CS-Heat exchanger Stainless Steel CS-L2 DI WATER CS-Heat exchanger Distribution Stainless Steel CS-L2.1 DI WATER CS-Heat exchanger Cell stack 1 Stainless Steel CS-L2.2 DI WATER CS-Heat exchanger Cell stack 2 Stainless Steel CS-L2.3 DI WATER CS-Heat exchanger H2&O2 system; H2 pressure control valve Stainless Steel CS-L3 DI WATER CS-Heat exchanger H2&O2 system; bleed valve Stainless Steel CS-L4 Hydrogen Cell stack 1 H2&O2 system; H2 separator Stainless Steel CS-L5 Hydrogen Cell stack 2 H2&O2 system; H2 separator Stainless Steel CS-L6 Oxygen Cell stack 1 H2&O2 system; O2 separator Stainless Steel CS-L7 Oxygen Cell stack 2 H2&O2 system; O2 separator Stainless Steel CS-L8 Cooling water Cooling tower system; Cooling water in CS-Heat exchanger Stainless Steel CS-L9 Cooling water 3-way valve Return heat exchanger Stainless Steel CS-L10 Cooling water 3-way valve Cooling towers; cooling water return Stainless Steel CS-L11 Cooling water Cooling tower system; Cooling water in DC power supply Stainless Steel CS-L12 Cooling water DC power supply Cooling towers; cooling water return Stainless Steel CS-L13 Nitrogen Nitrogen gas header Cell stacks 1&2 Stainless Steel DIW-L1 DI WATER H2&O2 system; H2 drain tank DI water tank Stainless Steel DIW-L2 DI WATER H2&O2 system; O2 drain tank DI water tank Stainless Steel DIW-L3 Nitrogen N2 gas supply DI water tank Stainless Steel DIW-L4.1 Nitrogen N2 gas supply H2&O2 system; H2 drain tank Stainless Steel DIW-L4.2 Nitrogen N2 gas supply Cell stack system; N2 supply Stainless Steel DIW-L5 DI WATER Demineralization system; circulation pump DI water tank Stainless Steel DIW-L6 Cooling water Cooling tower system; Cooling water in DIW heat exchanger Stainless Steel DIW-L7 DI WATER Di water tank DIW heat exchanger Stainless Steel DIW-L8 DI WATER DIW heat exchanger Resin Tanks Stainless Steel DIW-L9 Cooling water DIW heat exchanger Cooling towers; cooling water return Stainless Steel DIW-L10 DI WATER Resin tanks DI water tank Stainless Steel DIW-L11 DI WATER Resin tanks Feed pump 1&2 Stainless Steel DIW-L12 DI WATER Feed pump 1&2 H2&O2 system; O2 separator Stainless Steel DIW-L13 DI WATER Feed pump 1&2 DI water tank Stainless Steel H2O2-L1 DI WATER Cell Stack system; CS-heat exchanger H2 pressure control valve Stainless Steel H2O2-L2 Chilled water Chillers system; Chilled water in H2&O2- H2 Heat exchanger Stainless Steel H2O2-L3 chilled water Chillers system; Chilled water in H2&O2- O2 Heat exchanger Stainless Steel H2O2-L4 Hydrogen Cell stack system; cell stack 1&2 H2 separator Stainless Steel H2O2-L5 Nitrogen Air nitrogen system; N2 supply H2 analyzer Stainless Steel H2O2-L6 Nitrogen Air nitrogen system; N2 supply H2 drain tank Stainless Steel H2O2-L7 Oxygen Cell stack system; cell stack 1&2 O2 separator Stainless Steel H2O2-L8 DI WATER DI water system; feed pump 1&2 O2 separator Stainless Steel H2O2-L9 DI WATER Cell stack system; CS-heat exchanger O2 drain tank Stainless Steel H2O2-L10 DI WATER O2 drain tank DI water system; DI water tank Stainless Steel H2O2-L11 DI WATER O2 separator Cell stack system; CS-heat exchanger Stainless Steel H2O2-L12 DI WATER O2 demister O2 separator Stainless Steel H2O2-L13 Oxygen O2 separator H2&O2- O2 Heat exchanger Stainless Steel H2O2-L14 Oxygen H2&O2- O2 Heat exchanger O2 demister Stainless Steel H2O2-L15 chilled water H2&O2- O2 Heat exchanger Chillers system; buffer tank Stainless Steel H2O2-L16 Hydrogen H2 separator H2&O2- H2 Heat exchanger Stainless Steel H2O2-L17 DI WATER H2 demister H2 separator Stainless Steel H2O2-L18 DI WATER H2 separator H2 drain tank Stainless Steel H2O2-L19 chilled water H2&O2- H2 Heat exchanger Chillers system; buffer tank Stainless Steel H2O2-L20 Hydrogen H2&O2- H2 Heat exchanger H2 demister Stainless Steel H2O2-L21 Oxygen O2 demister Vent system; high pressure vent Stainless Steel H2O2-L22 Oxygen O2 demister Control valve and vent system Stainless Steel H2O2-L23 Oxygen O2 demister Vent system; low pressure Stainless Steel H2O2-L24 Oxygen O2 drain tank Vent system; high pressure vent Stainless Steel H2O2-L25 DI WATER H2 drain tank DI water system; DI water tank Stainless Steel H2O2-L26 Hydrogen H2 drain tank Vent system; Flare drum Stainless Steel H2O2-L27 Hydrogen H2 demister H2 pressure control valve Stainless Steel H2O2-L28 Hydrogen H2 demister Vent system; Flare drum Stainless Steel H2O2-L29 Hydrogen H2 pressure control valve H2 To User Stainless Steel H2O2-L30 Hydrogen H2 pressure control valve Vent system; Flare drum Stainless Steel V-L1 Oxygen O2 PDU system Vent silencer Stainless Steel V-L2 Oxygen H2&O2 system Vent silencer Stainless Steel V-L3 Oxygen Compressors system Vent silencer Stainless Steel V-L4 Hydrogen H2 PDU system Flare KO drum Stainless Steel V-L5 Hydrogen H2&O2 system Flare KO drum Stainless Steel V-L6 Raw water External Flare KO drum Stainless Steel V-L9 Hydrogen Flare KO drum Flare Stainless Steel V-L10 Oxygen O2 in Water out Stainless Steel H2-L1 Hydrogen Cell stack system H2 deoxo reactor Stainless Steel H2-L2 Cooling water Cooling tower system; Cooling water in Dryer cooler Hx and dryer cooler condensate pot Stainless Steel H2-L3 chilled water Chillers system; Chilled water in Dryer chiller Hx and dryer cooler condensate pot Stainless Steel H2-L4 Hydrogen H2 deoxo reactor Dryer Hx and condensate pot process Stainless Steel H2-L5 Cooling water H2 condensate pot Cooling towers; cooling water return Stainless Steel H2-L6 chilled water H2 condensate pot chillers system; chilled water return Stainless Steel H2-L8 Hydrogen H2 condensate pot H2 dryer absorbent vessels Stainless Steel H2-L9 Hydrogen H2 dryer absorbent vessels in loop H2 deoxo reactor Stainless Steel H2-L10 Hydrogen H2 dryer absorbent vessels out loop H2 dryer absorbent vessels out loop Stainless Steel H2-L11 Hydrogen H2 dryer absorbent vessels out loop H2 filter Stainless Steel H2-L12 Hydrogen H2 filter Regenerating was circulation pump Stainless Steel H2-L13 Hydrogen H2 filter To User Stainless Steel H2-L14 Hydrogen H2 filter Vent system; flare KO drum Stainless Steel O2-L1 Oxygen Cell stack system O2 deoxo reactor Stainless Steel O2-L2 Cooling water Cooling tower system; Cooling water in Dryer cooler Hx and dryer cooler condensate pot Stainless Steel O2-L3 chilled water Chillers system; Chilled water in Dryer chiller Hx and dryer cooler condensate pot Stainless Steel O2-L5 Cooling water O2 condensate pot Cooling towers; cooling water return Stainless Steel O2-L6 chilled water O2 condensate pot chillers system; chilled water return Stainless Steel O2-L7 Oxygen O2 deoxo reactor Dryer Hx and condensate pot process Stainless Steel O2-L8 Oxygen O2 condensate pot O2 dryer absorbent vessels Stainless Steel O2-L9 Oxygen O2 dryer absorbent vessels in loop O2 deoxo reactor Stainless Steel O2-L10 Oxygen O2 dryer absorbent vessels out loop O2 dryer absorbent vessels out loop Stainless Steel O2-L11 Oxygen O2 dryer absorbent vessels out loop O2 filter Stainless Steel O2-L12 Oxygen O2 filter Regenerating was circulation pump Stainless Steel O2-L13 Oxygen O2 filter Compressors system Stainless Steel O2-L14 Oxygen O2 filter Vent system Stainless Steel AN-L1 chilled water Chillers system; Chilled water in Nitrogen after cooler heat exchanger Stainless Steel AN-L2 Nitrogen External Liquid nitrogen storage and evaporator Hx Stainless Steel AN-L3 Nitrogen External Intermediate pressure plant users Stainless Steel AN-L4 Instrument Air External Plant users Stainless Steel AN-L5 chilled water Nitrogen after cooler Hx chillers system; chilled water return Stainless Steel AN-L6 Nitrogen External Compressor Stainless Steel AN-L7 Nitrogen Compressor Aftercooler Hx and tank Stainless Steel AN-L8 Nitrogen Aftercooler Hx return to compressor inlet Carbon Steel AN-L9 Nitrogen Aftercooler Hx Outside high-pressure loop, compressor inlet Carbon Steel AN-L10 Nitrogen Tank Plant users Carbon Steel CH-L1 Instrument Air Air nitrogen system Chilled water package Carbon Steel CH-L2 Cooling water Cooling tower system; Cooling water in Chilled water package Carbon Steel CH-L3 Cooling water Chilled water package Cooling towers; cooling water return Stainless Steel CH-L4 Chilled water Chilled water package Plant users Stainless Steel CH-L5 Chilled water Plant users Buffer tank Stainless Steel CH-L6 Glycol water Container Buffer tank Stainless Steel CH-L7 chilled water buffer tank water pump Stainless Steel CH-L8 chilled water Water pump buffer tank Stainless Steel CH-L9 chilled water Water pump Chilled water package Stainless Steel CP-L1 Oxygen O2 PDU system Compressor Stainless Steel CP-L2 Instrument Air Air nitrogen system Compressor process Stainless Steel CP-L3 Nitrogen Air nitrogen system Compressor process Stainless Steel CP-L4 chilled water chillers system; chilled water in Oxygen aftercooler Hx Stainless Steel CP-L5 chilled water Oxygen aftercooler Hx chilled water system; chiller water return Stainless Steel CP-L6 Oxygen Compressors Oxygen aftercooler Hx Stainless Steel CP-L7 Oxygen Compressor process Vent system Stainless Steel CP-L8 Oxygen Oxygen aftercooler Hx Plant users Stainless Steel CP-L10 Oxygen Oxygen aftercooler Hx Compressor process in Stainless Steel CT-L1 Cooling water water pumps Plant users Stainless Steel CT-L2 Cooling water Plant users Cooling towers Stainless Steel CT-L3 Instrument Air Air nitrogen system Cooling tower process Stainless Steel CT-L4 Raw water Distribution header Tank Stainless Steel CT-L5 Cooling water Tank water pumps Stainless Steel CT-L6 Cooling water water pumps Effluents Stainless Steel CT-L7 Cooling water water pumps filter and cooling towers Stainless Steel CT-L8 Treatment chemicals Treatment chemicals Tank Stainless Steel DM-L1 Instrument Air Air nitrogen system water purification package Stainless Steel DM-L2 DI WATER External water purification package Stainless Steel DM-L4 DI WATER Water purification package Reservoir Stainless Steel DM-L5 DI WATER Reservoir circulation pumps Stainless Steel DM-L6 DI WATER circulation pumps DIW polishing system Stainless Steel DM-L7 DI WATER circulation pumps Reservoir return Stainless Steel DM-L8 Chemicals DI water polishing water purification package Stainless Steel Annex 3 Effluent list ID. Description From To Basic pipe material E-L1 Waste water O2 PDU system Pit Carbon Steel E-L2 Waste water Vent system Pit Carbon Steel E-L3 Cooling water Cooling tower system; water blowdown Pit Carbon Steel E-L4 Waste water Demineralization system Pit Carbon Steel E-L5 NaOH External Pit Carbon Steel E-L6 HCL Container Tank Carbon Steel E-L8 Effluents Pit External / hold Carbon Steel E-L9 HCL Tank Pit Carbon Steel Annex 4 Electrical consumers list: Electrical consumers UNIT Item Tag DESIGNATION Supply Voltage (kV) PEM Electrolyzer PEM PEM electrolyzer 33 Circulation Pump PMP-CS cell stack circulation pump 0.23 Chilled Water package Chilled water package 0.23 Circulation Pump PMP-CH Chillers circulation pump 0.23 Circulation Pump PMP-DIW DI water circulation pump 0.23 Feed pump PMP1-DIW DI water feed pump 0.23 Feed pump PMP2-DIW DI water feed pump 0.23 Demineralization package Demineralization package 0.23 Circulation Pump PMP-DM Demineralization circulation pump 0.23 Regenerating gas pump PMP-H2 Regenerating H2 gas pump 0.23 Regenerating gas heater HT1-H2 Electrical heater for generating H2 gas 0.23 Deoxo heater HT2-H2 Deoxo heater 0.23 Filter FT-H2 Hydrogen gas filter 0.23 Regenerating gas pump PMP-O2 Regenerating O2 gas pump 0.23 Regenerating gas heater HT1-O2 Electrical heater for generating O2 gas 0.23 Deoxo heater HT2-O2 Deoxo heater 0.23 Filter FT-O2 Oxygen gas filter 0.23 Circulation Pump PMP-CT Cooling tower circulation pump 0.23 Fans Cooling tower fans motors 0.23 Filter FT1-CT Cooling tower water filter 0.23 Compressor CP-CP Oxygen compressors 0.23 Compressor CP-AN Air nitrogen compressor 0.23 Filter FT-AN Air nitrogen filter 0.23 Circulation Pump PMP1-E Effluents circulation pump 0.23 Circulation Pump PMP2-E Effluents extraction pump 0.23 Control elements Control elements for all components 0.23 Regular electrical consumer Everyday electrical consumers 0.23 DC Power supply CS_L1 CS_L2 CS_L2.1 CS_L2.2 CS_L4 CS_L5 CS_L6 CS_L7 CS_L8 CS_L9 CS_L10 CS_L10 CS_L10.1 CS_L10.2 CS_L13 CS_L13.1 CS_L13.2 CS_2.3 CS_L3 Cell Stack Module Cell Stack 2 Cell Stack 1 3-way CV Heat exchanger Circulation pump Hydrogen and oxygen system Nitrogen Gas Header Cooling water system O2 Separator Cooling tower system Hydrogen and oxygen system Bleed Valve Cooling tower system Cooling water return Hydrogen and oxygen system O2 Separator Hydrogen and oxygen system H2 Separator Hydrogen and oxygen system H2 pressure control valve Leyend Line color Type Blue DI water Red Hydrogen Green Oxigen Brown Raw water Cyan Cooling water Purple Chilled water Orange Nitrogen Yellow Power Gray Instrumental O2 Instrument Air N2 intermediate pressure Chilled water in O2 O2 Chilled water return COMPRESSORS TC PC PC PY FC TI PI Oxygen compressor Oxygen aftercooler O2 PDU system Air Nitrogen system Air Nitrogen system Chilled water system Vent system Plant users Chilled water system CP-L1 CP-L2 CP-L3 CP-L4 CP-L5 CP-L6 CP-L8 CP-L9 CP-L10 CP-L11 CP-L7 Cooling water supply Cooling water return Raw water Cooling water blowdown TC FILTER COOLING TOWER MM MPC TC Instrument Air QC Cooling Tower Tank Cooling water pumps LC valve QC valve ATM Plant users Plant users Air Nitrogen system Distribution header Effluents system Cooling water treatment chemicals CT-L1 CT-L2 CT-L3 CT-L4 CT-L5 CT-L6 CT-L7 CT-L8 CT-L9 Instrument Air DI water Demineralized water Waste water DEMINERALIZATION Water purification package LSH DW polishig package Vent to atmosphere Air Nitrogen system External DI water polishing system Effluents system DM-L1 DM-L2 DM-L3 DM-L4 DM-L5 DM-L6 DM-L7 DM-L8 resin generation chemicals Cooling water blowdown Waste water NAOH HCI Containers Effluents EFFLUENTS Waste water Waste water PH O2 PDU system Vent system Cooling tower system Demineralization system External Container system Externals / Hold E-L1 E-L2 E-L3 E-L4 E-L5 E-L6 E-L7 E-L8 E-L9 Tank Vent to ATM circulating pump Effluents pit Effluents pump O2 VENT H2 Flare KO drum NC valve 1 NC valve 2 Oxygen vent silencer O2 O2 H2 H2 Raw water waste water H2 flare waste water Effluents system Flare H2 PDU system External H2 and O2 system H2 and O2 system H2 PDU system O2 PDU system Compressors system V-L1 V-L2 V-L3 V-L4 V-L5 V-L6 V-L7 V-L8 V-L9 V-L10 Annex 6 ENVID Guideword Environmental Aspect / Causes General information (expander) Operating Conditions Environmental control measures Air emissions O2 emission to atmosphere O2, H2 and N2 are not concern / limited by TALUFT regulation Permanent (up to 8t/h) No consequences identified to environment H2 emission to atmosphere (analyzer vent only) Permanent (negligeable) Negligeable consequences to environment due to small quantity N2 emission to atmosphere Intermittent (negligible) No consequences identified to environment HCL emission to atmosphere Continuous (HCl tank Consequences unknown at this stage Liquid discharges Water from water treatment, water from cooling towers, water from PDU, water from electrolyzer is collected in effluent pit and drain to rainwater network traces of KOH, chemicals used in cooling tower, chemicals used for regeneration of water purification Continuous No consequences identified to environment Effluent pit and neutralization polishing bed 8-12 months Regeneration of bottles Waste management PDU catalyst Every 5 years Waste generation Waste management PDU absorbent Every 5 years Waste generation Waste management Stacks Every 10 years Regeneration of stacks by suppliers Recycle management Resources use Water use Continuous No consequences identified to environment Use of industrial water network Closed loop (Consumption of water only for make-up) Air use Continuous Potential legionella spreading to surroundings Use of biocide Safety distance and air inlet on other building Chemicals Chemicals used for cooling water tower (Biocide, anti-fouling, anti-corrosion, antiscale) Intermittent Soil and water pollution Physical presence Noise from O2 vent Continuous Noise generation Noise mitigation included in the design (O2 silencer) Noise from cooling water tower Continuous Noise generation Noise mitigation Noise from compressor Continuous Noise generation Noise mitigation included in the design Compressor building to mitigate noise generation Noise from rectifier Continuous Noise generation Noise mitigation included in the design Noise from ventilation of enclosure Continuous Noise generation Noise mitigation included in the design Electrolyzer building to mitigate noise generation Noise from chillers Continuous Noise generation Noise mitigation included in the design Chiller building to mitigate noise generation mitigate noise generation HAZID GENERAL Hazard Category Guideword Causes Consequences Barriers ENVIRONMENTAL HAZARDS Climate Extremes Low temperature potential freezing of water lines (Demin water supply, chilled water, etc.), leading to blockage, pipe rupture, equipment damage and leakage of water insulation or electrical heat tracing (Demin water) glycol injection (chilled water underground pipework (firewater) material selection and sizing of pipework (cooling water, intermediate cooling loop) drainage philosophy / procedure for long maintenance design (minimization of low point) potential freezing of DI water leading to blockage, pipe rupture, equipment damage and leakage of water HVAC drainage philosophy / procedure for long maintenance Malfunction of electrical equipment High temperature High temperature for operator inside electrolyzer room (due to process and external temperature) Ventilation of building High temperature for operator inside compressor room (due to process and external temperature) HVAC High temperature for operator inside rectifier room (due to process and external temperature) HVAC Reduction of the natural convection compromising the ventilation Snow Building collapsing due to weight of the snow Design of the building Operational procedure Rain / flooding Potential damage to equipment Design of building and Fog / humidity potential condensation on equipment leading to potential short circuit IP level suitable for 100% humidity level Potential corrosion on pipework / equipment corrosion protection ENVIRONMENTAL HAZARDS Subsidence Ground sliding Building collapsing due to soil composition Soil study ENVIRONMENTAL HAZARDS Discharges to Air Release of H2 No consequences identified (vent routed to flares) Release of O2 Enriched O2 atmosphere (increased ignition) location of vent according to safety distance with H2 equipment Cooling Oil / lube oil spillage Environmental issue (pollution) Oil pit building on retention Glycol spillage Environmental issue (pollution) building on retention water treatment drain Environmental issue (pollution) ph measurement water treatment / process drain pit HCl spillage Environmental issue (pollution) retention pit ENVIRONMENTAL HAZARDS Discharges to Soil PDU catalyst spillage Consequence unknown at this stage of the project HUMAN HAZARDS Adjacent industrial installation Explosion / fire from cracker LOC of H2 / O2 / etc., equipment damages, operator exposure (injuries) safety distances HUMAN HAZARDS On-site traffic Vehicle accident LOC of H2 / O2 / etc., equipment damages, operator exposure (injuries) site traffic rules dedicated loading area for N2, HCI WORKING HAZARDS Toxic HCl (30%) release Operator injuries due to toxic inhalation PPE Operational procedures Biocide chemicals for cooling tower Operator injuries due to toxic inhalation PPE Operational procedures WORKING HAZARDS Electromagnetism Hazard High voltage installation (transformers, rectifiers, bus bar, etc.) Operator exposure (for pacemaker holders) safety sign EMC design enclosure with LOTO Nearby equipment malfunction Process control and safety instrumented system EMC design WORKING HAZARDS Electrocution hazard High voltage installation (transformers, rectifiers, bus bar, etc.) Potential for electrical hazard, operator exposure (electrocution), fatality Electrical design physical barrier Restricted access and authorized personnel WORKING HAZARDS Other Lighting Working at height Risk of fall, operator injuries physical barriers on the Confined space operator trapped safety exit / escape way Hot surfaces Operator exposure (burns) PPE Insulation physical barrier Warning sign HAZID UTILITIES Hazard Category Guideword Causes Consequences Barriers PROCESS HAZARDS Release of Flammable Gas LOC of refrigerant for chiller Consequence unknown at this stage of the project LOC of H2 from bottle rack (used for calibration) (process upset, corrosion, operator error, leakage.) LOC of H2, creation of ATEX, potential of jet fire / explosion, operator exposure (fatalities), equipment damage ATEX Natural ventilation PROCESS HAZARDS Release of Flam. Liquid LOC of lube oil (process upset, corrosion, operator error, leakage.) LOC of lube oil, operational issue (spillage) without safety issue foreseen pit retention Inspection and maintenance procedures LOC of chemicals for cooling tower Consequences unknown PROCESS HAZARDS Release of Toxic Gas LOC of HCl (process upset, corrosion, operator error, leakage.) Liquid spillage, and potential vaporization of HCL, environmental issue (pollution), toxic dispersion leading to operator exposure PPE Inspection and maintenance procedures pit retention LOC of N2 inside building (compressor) (process upset, corrosion, operator error, leakage) Potential anoxia, operator exposure (fatality) PPE (personal portable O2 detector) Inspection and maintenance procedures safety sign PROCESS HAZARDS Release of Cryogenic Liq. LOC of liquid N2 (process upset, corrosion, operator error, leakage Creation of cloud leading to sight obstruction, potential operator exposure, structural damage safety distances for the structural damages material selection and design safety sign Fences PPE PROCESS HAZARDS Release of Pollutant Liq. LOC of glycol water (process upset, corrosion, operator error, leakage Environmental issue (pollution) Inspection and maintenance procedures LOC of NaOH on effluent treatment (process upset, corrosion, operator error, leakage.) Operator exposure (burns), environmental issue (pollution) PPE Inspection and maintenance procedures safety sign Safety shower / eye wash station Potential increased corrosion leading to structural damage material selection and design or elevated foundation Chemical liner in the pit Maintenance / inspection procedure Flange guards PROCESS HAZARDS Overpressure Valve closure (e.g., N2 compressor in blocked outlet and/or buffer drum blocked outlet) Compressor burst, equipment damage, LOC of N2, missile effect, operator exposure (fatality) PED design / PSV Process control and safety instrumented system Thermal expansion Over pressurization and potential pipe rupture, Proper design (e.g., LO valves, PSV, etc.) Cryogenic vaporization Over pressurization and potential pipe rupture, LOC (liquid N2), refer release of cryogenic liquid in this node Proper design (e.g., LO valves, PSV, etc.) Calibration bottles pressure regulator malfunction Over pressurization of the network leading to pipe rupture, LOC, operator exposure (injuries) PSV Inspection and maintenance procedures PROCESS HAZARDS Ignition sources Static electricity Potential source of ignition, risk of fire / explosion if LOC UTILITY HAZARDS Firewater Loss of fire water Potential escalation, equipment damage Fire team UTILITY HAZARDS Oil Loss of lube oil Equipment damages and loss of production Inspection and maintenance procedures UTILITY HAZARDS Heating /Cooling Medium Loss of cooling water Loss of cooling water to process section (stacks refer to node 05/06, Spare equipment (pumps, cooling tower) Production (kg/h) 2000 Hours year (h/year) 5000 Fixed costs 1.5% electricity price (eur/kwh) 0.096€ Year 1 2 3 4 5 6 7 8 9 10 electricity price (USD/MWh) 101.88€ Auxiliary consumption (kWh/kg) 3.18 3.18 3.18 3.18 3.18 3.18 3.18 3.18 3.18 3.18 SpecificPower Consumption (kWh/kg) 53 53.53 54.07 54.61 55.15 55.70 56.26 56.82 57.39 57.97 Total consumption (kWh/kg) 56.18 56.71 57.25 57.79 58.33 58.88 59.44 60.00 60.57 61.15 Production (kg H2 per year) 10000000.00 10000000.00 10000000.00 10000000.00 10000000.00 10000000.00 10000000.00 10000000.00 10000000.00 10000000.00 OPEX Variable costs 99.11% Electricity costs 53,802,012.96€ 54,309,579.12€ 54,822,220.94€ 55,339,989.18€ 55,862,935.10€ 56,391,110.49€ 56,924,567.62€ 57,463,359.33€ 58,007,538.95€ 58,557,160.37€ 0.50% Demi water 269,010.06€ 269,010.06€ 269,010.06€ 269,010.06€ 269,010.06€ 269,010.06€ 269,010.06€ 269,010.06€ 269,010.06€ 269,010.06€ 0.10% Raw water 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 0.10% Instrument Air 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 0.10% Nitrogen 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ Total 0.10% Other 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 53,802.01€ 561,480,474.06€ Fixed Costs (% CAPEX) 4,921,781.25€ 4,970,999.06€ 4,970,999.06€ 4,970,999.06€ 4,970,999.06€ 4,970,999.06€ 4,970,999.06€ 4,970,999.06€ 4,970,999.06€ 4,970,999.06€ Total OPEX 59,208,012.33€ 59,764,796.30€ 60,277,438.12€ 60,795,206.36€ 61,318,152.28€ 61,846,327.66€ 62,379,784.80€ 62,918,576.51€ 63,462,756.13€ 64,012,377.55€ 1 Year 10 Years accumulate Auxiliary consumption (MWh) 31800.00 3180000.00 Specific consumption (MWh) 530000.00 55449726.47 Total (MWh) 561800.00 58629726.47 OPEX 86.96% 2.61% 2.61% 1.74% 1.74% 1.74% 1.74% 0.87% 100.00% 1 2 3 4 5 6 7 8 Item Designation Electrolyzer & main equipment (chillers) O2 compressors Purification & dry units (O2&H2) Cooling towers Utilities (water, N2) Demineralized water Substation & electrical equipment Effluents pit & equipment Total AAcquisition cost 88,125,000.00€ 2,643,750.00€ 2,643,750.00€ 1,762,500.00€ 1,762,500.00€ 1,762,500.00€ 1,762,500.00€ 881,250.00€ 101,343,750.00€ 41.18% 40% B Construction & installation costs 66,093,750.00€ 528,750.00€ 528,750.00€ 352,500.00€ 352,500.00€ 352,500.00€ 352,500.00€ 176,250.00€ 68,737,500.00€ 27.93% 30% C Engineering & project 22,031,250.00€ 660,937.50€ 660,937.50€ 440,625.00€ 440,625.00€ 440,625.00€ 440,625.00€ 220,312.50€ 25,335,937.50€ 10.30% 10% D Pre com, com, and start up 2,203,125.00€ 66,093.75€ 66,093.75€ 44,062.50€ 44,062.50€ 44,062.50€ 44,062.50€ 22,031.25€ 2,533,593.75€ 1.03% 1% EContingency 22,031,250.00€ 660,937.50€ 660,937.50€ 440,625.00€ 440,625.00€ 440,625.00€ 440,625.00€ 220,312.50€ 25,335,937.50€ 10.30% 10% FOwner costs 19,828,125.00€ 594,843.75€ 594,843.75€ 396,562.50€ 396,562.50€ 396,562.50€ 396,562.50€ 198,281.25€ 22,802,343.75€ 9.27% 9% GFinal Costs 220,312,500.00€ 5,155,312.50€ 5,155,312.50€ 3,436,875.00€ 3,436,875.00€ 3,436,875.00€ 3,436,875.00€ 1,718,437.50€ 246,089,062.50€ 100.00% 100% PEM Electrolyzer % over all plant 35.81% PROJECT CAPEX K10 246,089,062.50€ EUR SUM NUM 720092043.56 OPEX 2% to 5% CAPEX 12,304,453.13€ EUR SUM DENOM 77217349.29 5% % LCOH (EUR/kg) 9.33 53.00 kWh/kg H2 1.00E+07 kg/year H2 5000.00 h/year Year 0 1 2 3 4 5 6 7 8 9 10 CAPEX 246,089,062.50€ 0 0 0 0 0 0 0 0 0 0 OPEX -€ 59,208,012.33€ 59,764,796.30€ 60,277,438.12€ 60,795,206.36€ 61,318,152.28€ 61,846,327.66€ 62,379,784.80€ 62,918,576.51€ 63,462,756.13€ 64,012,377.55€ PRODUCTION 010000000 10000000 10000000 10000000 10000000 10000000 10000000 10000000 10000000 10000000 NUM 246,089,062.50€ 56,388,583.17€ 54,208,432.02€ 52,069,917.39€ 50,016,366.73€ 48,044,376.79€ 46,150,681.93€ 44,332,148.43€ 42,585,769.18€ 40,908,658.45€ 39,298,046.97€ DENOM 09523809.524 9070294.785 8638375.985 8227024.748 7835261.665 7462153.966 7106813.301 6768393.62 6446089.162 6139132.535 Interes rate Specific consumption Production Operating time CAPEX 25% 86.96% 2.61% 2.61% 1.74% 1.74% 1.74% 1.74% 0.87% 100.00% 1 2 3 4 5 6 7 8 Item Designation Electrolyzer & main equipment (chillers) O2 compressors Purification & dry units (O2&H2) Cooling towers Utilities (water, N2) Demineralized water Substation & electrical equipment Effluents pit & equipment Total AAcquisition cost 58,750,000.00€ 1,762,500.00€ 1,762,500.00€ 1,175,000.00€ 1,175,000.00€ 1,175,000.00€ 1,175,000.00€ 587,500.00€ 67,562,500.00€ 41.18% B Construction & installation costs 44,062,500.00€ 352,500.00€ 352,500.00€ 235,000.00€ 235,000.00€ 235,000.00€ 235,000.00€ 117,500.00€ 45,825,000.00€ 27.93% C Engineering & project 14,687,500.00€ 440,625.00€ 440,625.00€ 293,750.00€ 293,750.00€ 293,750.00€ 293,750.00€ 146,875.00€ 16,890,625.00€ 10.30% D Pre com, com, and start up 1,468,750.00€ 44,062.50€ 44,062.50€ 29,375.00€ 29,375.00€ 29,375.00€ 29,375.00€ 14,687.50€ 1,689,062.50€ 1.03% EContingency 14,687,500.00€ 440,625.00€ 440,625.00€ 293,750.00€ 293,750.00€ 293,750.00€ 293,750.00€ 146,875.00€ 16,890,625.00€ 10.30% FOwner costs 13,218,750.00€ 396,562.50€ 396,562.50€ 264,375.00€ 264,375.00€ 264,375.00€ 264,375.00€ 132,187.50€ 15,201,562.50€ 9.27% GFinal Costs 146,875,000.00€ 3,436,875.00€ 3,436,875.00€ 2,291,250.00€ 2,291,250.00€ 2,291,250.00€ 2,291,250.00€ 1,145,625.00€ 164,059,375.00€ 100.00% PEM Electrolyzer % over all plant 35.81% PROJECT CAPEX K10 164,059,375.00€ EUR SUM NUM 638062356.06 OPEX 2% to 5% CAPEX 8,202,968.75€ EUR SUM DENOM 77217349.29 5% % LCOH (EUR/kg) 8.26 53.00 kWh/kg H2 1.00E+07 kg/year H2 5000.00 h/year Year 0 1 2 3 4 5 6 7 8 9 10 CAPEX 164,059,375.00€ 0 0 0 0 0 0 0 0 0 0 OPEX -€ 59,208,012.33€ 59,764,796.30€ 60,277,438.12€ 60,795,206.36€ 61,318,152.28€ 61,846,327.66€ 62,379,784.80€ 62,918,576.51€ 63,462,756.13€ 64,012,377.55€ PRODUCTION 010000000 10000000 10000000 10000000 10000000 10000000 10000000 10000000 10000000 10000000 NUM 164,059,375.00€ 56,388,583.17€ 54,208,432.02€ 52,069,917.39€ 50,016,366.73€ 48,044,376.79€ 46,150,681.93€ 44,332,148.43€ 42,585,769.18€ 40,908,658.45€ 39,298,046.97€ DENOM 09523809.524 9070294.785 8638375.985 8227024.748 7835261.665 7462153.966 7106813.301 6768393.62 6446089.162 6139132.535 Interes rate Specific consumption Production Operating time CAPEX 50% 86.96% 2.61% 2.61% 1.74% 1.74% 1.74% 1.74% 0.87% 100.00% 1 2 3 4 5 6 7 8 Item Designation Electrolyzer & main equipment (chillers) O2 compressors Purification & dry units (O2&H2) Cooling towers Utilities (water, N2) Demineralized water Substation & electrical equipment Effluents pit & equipment Total AAcquisition cost 29,375,000.00€ 881,250.00€ 881,250.00€ 587,500.00€ 587,500.00€ 587,500.00€ 587,500.00€ 293,750.00€ 33,781,250.00€ 41.18% 40% B Construction & installation costs 22,031,250.00€ 176,250.00€ 176,250.00€ 117,500.00€ 117,500.00€ 117,500.00€ 117,500.00€ 58,750.00€ 22,912,500.00€ 27.93% 30% C Engineering & project 7,343,750.00€ 220,312.50€ 220,312.50€ 146,875.00€ 146,875.00€ 146,875.00€ 146,875.00€ 73,437.50€ 8,445,312.50€ 10.30% 10% D Pre com, com, and start up 734,375.00€ 22,031.25€ 22,031.25€ 14,687.50€ 14,687.50€ 14,687.50€ 14,687.50€ 7,343.75€ 844,531.25€ 1.03% 1% EContingency 7,343,750.00€ 220,312.50€ 220,312.50€ 146,875.00€ 146,875.00€ 146,875.00€ 146,875.00€ 73,437.50€ 8,445,312.50€ 10.30% 10% FOwner costs 6,609,375.00€ 198,281.25€ 198,281.25€ 132,187.50€ 132,187.50€ 132,187.50€ 132,187.50€ 66,093.75€ 7,600,781.25€ 9.27% 9% GFinal Costs 73,437,500.00€ 1,718,437.50€ 1,718,437.50€ 1,145,625.00€ 1,145,625.00€ 1,145,625.00€ 1,145,625.00€ 572,812.50€ 82,029,687.50€ 100.00% 100% PEM Electrolyzer % over all plant 35.81% PROJECT CAPEX K10 82,029,687.50€ EUR SUM NUM 556032668.56 OPEX 2% to 5% CAPEX 4,101,484.38€ EUR SUM DENOM 77217349.29 5% % LCOH (EUR/kg) 7.20 53.00 kWh/kg H2 1.00E+07 kg/year H2 5000.00 h/year Year 0 1 2 3 4 5 6 7 8 9 10 CAPEX 82,029,687.50€ 0000000000 OPEX -€ 59,208,012.33€ 59,764,796.30€ 60,277,438.12€ 60,795,206.36€ 61,318,152.28€ 61,846,327.66€ 62,379,784.80€ 62,918,576.51€ 63,462,756.13€ 64,012,377.55€ PRODUCTION 010000000 10000000 10000000 10000000 10000000 10000000 10000000 10000000 10000000 10000000 NUM 82,029,687.50€ 56,388,583.17€ 54,208,432.02€ 52,069,917.39€ 50,016,366.73€ 48,044,376.79€ 46,150,681.93€ 44,332,148.43€ 42,585,769.18€ 40,908,658.45€ 39,298,046.97€ DENOM 09523809.524 9070294.785 8638375.985 8227024.748 7835261.665 7462153.966 7106813.301 6768393.62 6446089.162 6139132.535 Interes rate Specific consumption Production Operating time CAPEX 75% 1 2 3 4 5 6 7 8 Item Designation Electrolyzer & main equipment (chillers) O2 compressors Purification & dry units (O2&H2) Cooling towers Utilities (water, N2) Demineralized water Substation & electrical equipment Effluents pit & equipment Total AAcquisition cost -€ -€ -€ -€ -€ -€ -€ -€ -€ B Construction & installation costs -€ -€ -€ -€ -€ -€ -€ -€ -€ C Engineering & project -€ -€ -€ -€ -€ -€ -€ -€ -€ D Pre com, com, and start up -€ -€ -€ -€ -€ -€ -€ -€ -€ EContingency -€ -€ -€ -€ -€ -€ -€ -€ -€ FOwner costs -€ -€ -€ -€ -€ -€ -€ -€ -€ GFinal Costs -€ -€ -€ -€ -€ -€ -€ -€ -€ PEM Electrolyzer % over all plant PROJECT CAPEX K10 -€ EUR SUM NUM 474002981.06 OPEX 2% to 5% CAPEX -€ EUR SUM DENOM 77217349.29 5% % LCOH (EUR/kg) 6.14 53.00 kWh/kg H2 1.00E+07 kg/year H2 5000.00 h/year Year 0 1 2 3 4 5 6 7 8 9 10 CAPEX -€ 0000000000 OPEX -€ 59,208,012.33€ 59,764,796.30€ 60,277,438.12€ 60,795,206.36€ 61,318,152.28€ 61,846,327.66€ 62,379,784.80€ 62,918,576.51€ 63,462,756.13€ 64,012,377.55€ PRODUCTION 010000000 10000000 10000000 10000000 10000000 10000000 10000000 10000000 10000000 10000000 NUM -€ 56,388,583.17€ 54,208,432.02€ 52,069,917.39€ 50,016,366.73€ 48,044,376.79€ 46,150,681.93€ 44,332,148.43€ 42,585,769.18€ 40,908,658.45€ 39,298,046.97€ DENOM 09523809.524 9070294.785 8638375.985 8227024.748 7835261.665 7462153.966 7106813.301 6768393.62 6446089.162 6139132.535 Interes rate Specific consumption Production Operating time CAPEX 100% M Circulation Pump Chilled water package M M Circulation Pump M M Feed pump 1 Feed pump 2 Demineralization unit package M DM circulation Pump M Regenerating gas pump Regenerating gas Heater Deoxo heater Filter M Regenerating gas pump Regenerating gas Heater Deoxo heater Filter Cell Stack Chillers System Circulation Pump DI Water Polishing system Demineralization system H2 PDU system O2 PDU system M Circulation pump Cooling tower system M Fan Motors Filter Compressor Filter Air Nitrogen system Compressors system O2 compressor Effluents system M Circulation pump M Effluents pump 110 kV Transformer 110 / 30 kV Transformer 110 / 30 kV 30 kV 50 Hz 30 kV 50 Hz Transformer 30 / 6 kV Transformer 30 / 6 kV 6 kV 50 Hz 6 kV 50 Hz 400/230 V 400/230 V 400/230 V 400/230 V 400/230 V 400/230 V 400/230 V 400/230 V 400/230 V Transformer 6 / 0.4 kV Transformer 6 / 0.4 kV Transformer 6 / 0.4 kV Transformer 6 / 0.4 kV Transformer 6 / 0.4 kV Transformer 6 / 0.4 kV Transformer 6 / 0.4 kV Transformer 6 / 0.4 kV Transformer 6 / 0.4 kV Transformer 6 / 0.4 kV Control Elements 400/230 V Transformer 6 / 0.4 kV Cell Stack 1 to 22; 5 MW each Module 1 100 MW Uninterruptible power supply for PLC