Table of Contents

1.Introduction and Governing Reactions 2

2. .Material Balance
2.1.Considering the overall balance 4
2.2.Individual Balance for the Electrolyser. 4
2.3.Individual Balance for the Catalytic Deoxidiser 5
3.Energy Balance
3.1.Electricity Consumption in the Electrolysers.. 6
3.2.Heating up of water stream entering the Electrolyser battery. 8
4.Equipment Design. 9
5. Cost Estimation
5.1.Capital Cost 10
5.2.Summary of Capital Cost 10
5.3.Operating Cost.. 11
5.4.Investment analysis 11
6.Conclusion. 12
7.References. 13

Plant Design for Electrolysis Plant

1.Introduction and Governing Reactions
With increasing demand for efficient and renewable energy to power our society, biomass and
other renewable energy are constantly being revised as a feasible alternative to fossil fuels.
Especially hydrogen with the next generation of fuel cells may prove to be a successful and
sustainable alternative to oil. The most commonly used processes for hydrogen production today
is oil cracking and steam reforming of natural gas, both based on fossil fuel. And in this case we
shall aim to establish a plant for the production of Hydrogen using Water Electrolysis.
The Governing reactions may be summarised as, The electrolyser consists of a power source
which transports electrons from the electrolyte at the anode to the electrolyte at the cathode.
The electrolyte sections are separated by a diaphragm or a membrane which permits OH- ions
and the electric current to pass through, whereas the actual electrolyte is stationary. This results
in the following reactions at the electrodes:

Pure water has low conductivity and is thus not suitable. Therefore, a water solution usually of
KOH, NaOH or HCl is used to increase the conductivity. With few exceptions, the electrolyte in
conventional electrolysers has a 25-35 wt% content of KOH. The classical, monopolar electrolyser
is constructed as shown in figure:

Figure 1. The monopolar water electrolyser construction, with potassium hydroxide added to
improve the performance

However it is intended to design a plant Based on The Bipolar Alkaline Based( KOH) Electrolyser.

Fig2:. a) Cell walls; b) Electrolyte; c) Cathode; d) Anode; e) Hydrogen outlet; f)Oxygen outlet; g)
Gas collector; h) Diaphragm; i) Outer cathode; j) Outer anode; k) Bipolar electrode; l) Insulation
The Plant is intended to have a design capacity of 14000 tonnes a year.
In order to maintain the techno economic feasibility of the plant additional units may be added in
the future as electrolysis is a power hungry procedure.
Considering the basic schematic of the initial design.

Figure 3. Process diagram of an electrolysis unit with the most important components
a) Rectifier unit; b) Process water demineraliser ion exchange unit; c) Electrolytic cell's water
electrolyser; d) Gas separator and cooler; e) Gas scrubber; f) Electrolyte tank and transfer pump;
g) Gas holder; h) Filter; i) Compressor; j) Gas purifier; k) Drying; l) High-pressure storage tank
and cylinder filling station

2.Material Balance:

Figure 4. Diagram for Simplified Material Balance.

2.1.Considering the overall balance:
Yearly Production: 14000 tonnes
Considering 350 working days=14000/350= 40 tonnes a day.
And since a day comprises of eight working hours= 40/8=5 tonnes per hour.
So from the Cell Reaction mentioned above:
5 tonnes of hydrogen gas=5000 kg of H2 =2500 kgmol of H2.
So, 2500 kgmol of H2 needs 2500 kgmol of water=2500 X 18=45000kg of water per hour i,e
45000 l of water per hour.
And O2 produced will be 40000 kg per hour.
2.2.Individual Balance for the Electrolyser:
As the performance of most electrolysers vary. We first set out to select the required model of our
electrolyser:

The optimal choice of electrolyser is the Lurgi type. This unit combines a high output pressure of
both oxygen and hydrogen (30 bars) and operates at a high temperature. Moreover, the market
position of this equipment is excellent, with more than 100 installed systems worldwide. To
4

supply the demanded production rate of hydrogen, a number of parallel units will be needed. The
maximum production rate for a single Lurgi electrolyser is 760 Nm3/h. The pressurised oxygen
product is used in the gasifier. The oxygen residuals in the hydrogen stream are removed in a
catalytic deoxidiser.

However, the Lurgi electrolyser is a very complex and expensive choice and therefore not a
suitable choice for this project. Instead the atmospheric electrolyser from Norsk Hydro is chosen.
When using an atmospheric electrolyser two compressors have to be installed, one for the
hydrogen and one for the oxygen. The maximum production rate for a single electrolyser is 100
Nm3/h. To supply the demanded production of hydrogen several electrolysers will be needed.
So applying the material balance on a single electrolyser unit:
5 tonnes of Hydrogen=5000 kg=5000/0.0898=55679.287 Nm3 of H2.
Which will require 55679.287/100=556.79287557 of such units.
And each unit will be processing nearly nine kilograms of hydrogen and 72 kilograms of oxygen
each hour.
Input to Electrolyser units:
Material
Water
Potassium Hydroxide

Quantity per hour

45000 kg
25% of 45000=11250 kg

Output from Electrolyser Units:

Material
Oxygen stream
Hydrogen stream
Impurities

mixed

with

Quantity per hour

40000 kg
Oxygen 5000 kg( with trace amounts of oxygen and
impurities)

2.3.Individual Balance for the Catalytic Deoxidiser:

Input to Deoxidiser:
Material
Impure Hydrogen Stream

Quantity per hour

5000 kg(with trace amount of oxygen and
impurities)

Output from Deoxidiser:

Material
Pure Hydrogen
Oxygen
Water Vapour and Lye

Quantity per hour

5000 kg
0.5 kg
0.5 kg
5

3.Energy Balance:
The main consumers of energy in the process involves:
1. Electricity Consumption in the Electrolysers
2. Compression of product gasses for liquefaction and storage.
3. Heating up of water stream entering the Electrolyser battery.

3.1.Electricity Consumption in the Electrolysers:

The principle of water electrolysis is rather simple. Applying direct current to water causes
electrolysis, splitting water into hydrogen and oxygen through the reaction shown in shown in
Eqs. 13.

Through this reaction, two molecules of water are decomposed and hydrogen evolves in the
cathode. In the anode, oxygen evolves and at the same time one molecule of water is regenerated.
As a result, one molecule of water is decomposed and another molecule of water moves to the
anode.
In industrial alkaline water electrolysis, 2040% sodium hydroxide or potassium hydroxide
aqueous solution is used for electrolyte instead of pure water, since pure water is highly resistive
to electricity.
Er, the reversible potential (equilibrium potential, namely theoretical voltage of electrolysis) is
given by following equation.

= 0

where E0 is standard equilibrium potential, R is gas constant, T is absolute temperature, P0 and

P are vapor pressure of pure water and electrolyte respectively. E0 is given by Go/2F, Go is
increment of Gibbs free energy and F is Faraday constant (96519.4 coulomb), which is 1.226 V
under 298 K and 1 atm. This is slightly higher than the decomposition voltage of pure water under
the same condition. Electricity required to produce 1 N m3of hydrogen is, from Faraday's law,
2393 Ah (Ampere hours). As this reaction proceeds almost quantitatively, the minimum energy
required is 2.94 kWh for 1 cubic meter of hydrogen. Since Er is theoretical equilibrium potential,
actual cell voltage needed to continue the reaction is higher with the addition of ohmic loss of
electrolyte and diaphragm and overvoltage (overpotential) by electrode reaction.

Actual cell voltage E is calculated according to the following equation.

where E is electrolysis voltage (cell voltage), Er is reversible potential (reversible voltage,

theoretical voltage of electrolysis), Eir is overvoltage (overpotential), and Eohm is ohmic loss.

Reversible potential is theoretically decided according to the reaction condition, but overvoltage
and ohmic loss vary with activity of electrodes and cell design. Overvoltage is loss due to
resistance by the chemical reaction rate. To drive the chemical reaction of electrolysis, extra
energy is required in addition to the reversible potential which corresponds to a zero reaction
rate. In water electrolysis, overvoltage is decided by the reaction rate at the electrodes. Therefore
electrodes with highly active electrocatalysts can reduce the overvoltage. Ohmic loss is mainly
caused by electric resistance of electrolyte, which can be reduced by shortening the distance
between anode and cathode. Ohmic loss is also caused by electric resistance of circuitry. Both
overvoltage and ohmic loss increase with the increasing current density (current per unit area of
electrode), hence increase of cell voltage and, therefore, increase of electric power to make
hydrogen.

The water electrolyzers currently used in industry work at a cell voltage of 1.82.2 volts
corresponding to 4.35.3 kWh per N m3 hydrogen. N stand for normal condition that means
the volume at 0oC and 1atm pressure.

So, Considering the fact that we plan to produce 5000 kg of H2 in one hour.
5000 kg of H2=5000/0.0898=55679.287 Nm3 of H2.
55679.287 Nm3 of H2=55679.287 X 4.3=239420.9354 kWh
Hence, 239420.9354 kWh must be supplied to the Electrolyser Battery Alone.

3.2.Heating up of water stream entering the Electrolyser battery.

45000 kg of water must be supplied to the Electrolyser.
Assuming the Provided Demineralised water Entering at a temperature of 300C.
The additional energy to be provided is:
45000 X 4.2 X (90- 30)=11340000kJ=11340000 X 0.278=3152520 kWh.
However a major part of this value may be obtained using the heated streams of Oxygen and
Hydrogen in a Heat Exchanger, as illustrated in the figure:
Hydrogen in the exchanger will compensate for about:
5000 X 0.0205 X (90-35) X0.278=1567.225kWh.
Oxygen in the stream will compensate for about:
40000 X 0.9 X (90-35) X 0.278=550440kWh.
So, Additional heat to be provided for heating the water:
3152520 kWh -1567.225kWh-550440kWh=2600512.775kWh.

Figure 5: Simplified Diagram for Energy Balance Scheme

4.Equipment Design:
4.1.Heat Exchanger 1:
LMTD:((90-33)-(35-30))/(log(90-33)/(35-30)=49.2002
Area=552007.225/49.2002=11219.61m2

4.2.Heat Exchanger 2:
Area= 2600512.775kWh/(90-33)=45623.03114m2

4.3.Boiler for Steam Generation:

Utilizing a Natural Gas Fed Furnace type boiler: 630 kW/m2
Hence Area of Boiler required=2600512.775/630=4127.798m2.
4.4.Norsk Hydro Electrolyser Unit:

5.Cost Estimation:

5.1.Capital Cost:

Item
Electrolysis
Hydro Electrolysis System
Oxygen Compressor
Hydrogen Compressor

Item Cost in Rs. Rs.

18767962500
18381000000
136703040
250259460

Heat Exchangers
HEX1
HEX2

189268500
30946920

Power Generation
Steam Boiler

180262080

Pumps
P1
P2
Storage Vessels
Hydrogen
Oxygen
Total Module Cost

220215420

180262080

14123100
8473860
5649240
138663360
15407040
123256320
19321226460

*Considering each electrolyser unit costs 0.55MU$

5.2.Summary of Capital Cost:

SUMMARY OF CAPITAL COST

Item
module cost
contracting & contingency
Auxiliary facilities
Total cost

Cost in RS.
RS.
19321226460
1238337900
2063896500
22623460860

10

5.3 Operating Cost:

Material storage
Hydrogen
Spare parts
Oxygen

829440
41277960
6635520

FIXED CAPITAL

48742920

Raw material
Water
Eletricity
Operating staff
Management
Lab work
Maintenance
Wast treatment

4947060
1516273680
61714263
9257160
9257160
412779300
7622820

DIRECT OPERATING COST

2021851443

Overhead for staff

administration
R&D
INDIRECT OPERATING COST
TOTAL

48742920

2021851443

52457160
13114260
50929920
116501340

116501340

2187095703

2187095703

5.4.Investment Analysis:

INVESTMENT ANALYSIS:
ITEM
COST IN RS.
Depreciation of capital cost
1512801300
Operating cost
5093122183
Annual production cost /kg
833094120
Production cost /kg H2
296.4
Electricity price
4.44
Vkk current
360
Interest rate
10%
Economic life span
15 yrs
Hydro electrolyser system cost/unit
45000000

11

6.Conclusion:
This Plant will yield a Total Profit of Rs. 13330103595 over the period of 15 yrs. Hence the set up
is feasible. Oxygen however has very small contribution to the profit and is mainly dependent on
Hydrogen gas obtained at a purity of 99.6%.

12

7.References:
1.KET050 Feasibility Studies on Industrial Plants Dept of Chemical Engineering, Lund Institute of
Technology
2. ENERGY CARRIERS AND CONVERSION SYSTEMS Vol. I - Alkaline Water Electrolysis - Isao Abe
3. Efficiency Calculation and Configuration Design of a PEM Electrolyzer System for Hydrogen
Production.Houcheng Zhang, Shanhe Su, Guoxing Lin*, Jincan Chen**Department of Physics,
Xiamen University, Xiamen 361005, Peoples Republic of China. Int. J. Electrochem. Sci., 7 (2012)
4143 4157.

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