(168a) Advanced Process Solutions for Blue Hydrogen and Refinery Decarbonization Enabling Net-Zero Targets

With the global drive for the imminent energy transition, hydrogen undoubtedly holds the major and integral role as an enabler for the decarbonization pathways and realization of net-zero targets. For addressing such projected hydrogen demand for such transition and eventual clean energy landscape, the progression of fossil based grey to blue hydrogen generation based on added CO2 capture inevitably holds a key and unavoidable role, while green H2 (based on water electrolysis using renewable power) projected to catch up at a higher pace in the much longer term.

Over the years, hydrogen has been carrying its pivotal role in petroleum refining for catering to the ever increasing demand and clean fuels mandates, thereby also aptly calling for advanced hydrogen management including optimized on-purpose H2 generation for enhancing overall refinery profitability

In the realm of energy transition, the targets have progressed from H2 management towards CO2 management, while also faced with the challenge that most of the present day H2 generation itself caries a large C-footprint (of 9-12 ton per ton H2). However, so far only marginal reduction in CO2 avoidance have been realized in absence of strong global statuary framework.

In such context, the “hard-to-abate” industrial sectors like refining and others involving high temperature processing needing fossil based fuel firing, are expected to follow the “blue pathways” based on CCUS in support of recognized fossil-continuity. With a refinery having inherently multiple fuel-fired heaters, for aiming carbon avoidance of > 85%, it first calls for post-combustion CO2 capture, However, it has been largely constrained by its cost and energy intensity. Even with various continuing technological developments, there is not yet a clearly winning process which is cost-effective, reliable and sufficiently deployed commercially. Thus it makes it quite challenging and perhaps risky venture on a larger scale, even with given incentives.

In addressing the above trends, ZoneFlow Reactor Technologies LLC developed an advanced and novel process re-configuration of the conventional H2 plant flowsheet called “Z-H2” technology which allows >95% decarbonization by deploying only the well-proven and cost-effective Pre-combustion CO2 removal from high pressure clean syngas. Further combining with its innovative structured catalyst for steam reforming replacing the conventional pellets for enhancing efficiency and 15-25% productivity, it offers an attractive process technology solution for blue H2 generation, which is also ready to implement.

The Z-H2 process concept is based on recycling and retaining the total carbon input within the process while having SMR firing with nearly pure H2. The H2 plant capacity though becoming much larger, also for catering for the H2 fuel requirements for rest of the refinery units replacing the refinery fuel gas, the overall economics remains attractive in the wake of eliminating the post-combustion CO2 capture while also achieving the higher CO2 capture level of 95% while also accounting for parasitic energy footprint.

The paper will include comparative techno-economic analysis for blue H2 generation with natural gas feedstock in conjunction with integrating the advanced features of utilization of refinery off gases and expanded hydrogen network for the lowering the C-footprint of a refinery.

Decarbonizing the hydrogen generation via centralized pre-combustion capture within the expanded and new H2 plants using Z-H2 process technology for producing extra hydrogen for blending or replacing the hydrocarbon fuels in the refinery heaters will prove to be an effective, proven, and economical route for decarbonization and targeted energy transition going forward, while harnessing the imminent and future carbon avoidance mandates.