CUSTOMER TECHNICAL

DESCRIPTION HY.GEN 50

Björn Wellenberg

HYG-HGSL-SP.014
 1 Introduction and general description

HyGear offers the Hy.GEN 50, a Hydrogen Generation System capable of producing
47 Nm3/h (50 Sm3/h) of hydrogen gas at a purity of 99,5%. A higher required purity results
in a lower maximum output of up to 43 Nm3/h (45 Sm3/h) at a purity of 99,999%.
This system uses two proprietary technologies: the Highly Integrated Steam Reforming
technology HISR® and the Quality cycle Vacuum Pressure Swing Adsorber technology
Qcycle®-VPSA. These two technologies are the base of the HyGear hydrogen generation
systems.
The Hy.GEN 50 is a standalone operating system that can easily be installed on any site.
Multiple systems can be installed in cascade when a higher capacity is required.

The Hy.GEN 50 consists of five modules:

• Fuel preparation (FPM)

• Hydrogen generation (HGM)
• Hydrogen clean-up (HCM)
• Hydrogen buffer (HBM)
• System control (SCM)
• Reformate cooling module (RCM)

Next to the state of the art reforming process combined with an advanced VPSA process, the
Hy.GEN 50 uses an advanced integrated heat exchange, which provides the necessary heat for
the incoming natural gas/steam mixture. The required steam for the process is provided by an
integrated heat exchange with the burner exhaust gasses.

The high level of integration and full utilization of the VPSA off-gas yields a very high efficiency
in hydrogen production. Furthermore, the design for a single pressure stage means there is no
compression required between the reformer and VPSA, resulting in low investment costs, high
overall efficiency and safe operation.

The system includes natural gas desulfurization and can therefore be connected directly to the
natural gas line. Other connections required are: feed water, electricity (for controls and
auxiliaries) and compressed air (for valves).

The system requires natural gas at a pressure of 10,5 ± 0,5 bar(g). If this is not available, a
natural gas compressor can be added (option). The hydrogen delivery pressure has a maximum
of 7,5 bar(g). In case this is not sufficient for the customer, a hydrogen compressor or booster
can be added (option).

All the hardware is situated in a container with the following dimensions: 6,1m x 2,6m x 2,44m.
To be clearly recognizable as a HyGear product, the system bears the HyGear logo and is
painted in the HyGear colour scheme (completely white with blue HyGear logos). On customer
demand it is possible to provide different colour schemes.

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 The system control unit is placed in a cabinet, which houses inside the container. The heart of
the control is formed by a Siemens PLC system operating on Step 7 programming.
The entire system is CE certified. This certification includes PED approval since the pressure in
the system exceeds 0,5 bar(g).

In figure 1 the flow diagram of the Hy.GEN 50 system is given. The necessary external feed
lines and the internal processes and internal flows are visualized in this diagram. The
specifications of all the external input and output gas/fluid flows are listed in Table 1.

Figure 1: flow diagram Hy.GEN 50

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 1. Reformer Unit 7. Electronics Cabinet 13. Burner Air Blower 19. Hydrogen Storage
2. Steam Generator 8. Coolant Heater 14. Reformate Cooler 20. VPSA purge Vessels
3. Water Knock out 9. Expansion Vessel 15. Ventilation Fan 21. VPSA Water Vessel
4. DI Water Storage 10. Reverse Osmosis Unit 16. Desulfurization Vessel 22. VPSA Vacuum Pump
5. Water Gas Shift 11. Coolant Pump 17. VPSA Vessels
6. DI water pumps 12. Electro Deionisation Module 18. Off-gas Storage

Figure 2: Internal system overview

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 Fuel preparation module

Natural gas section:

The natural gas is desulfurized to avoid problems in the reforming process related to
contamination. The Fuel Preparation Module is designed to prepare natural gas at the right
pressure and remove contaminants from the feed stream such as sulfur.
A module, specifically configured for the customer’s local natural gas composition will be
included in the Hy.GEN 50 system. This means that amongst others, a sulfur removal system
removes locally used odorants from the feed stream.

Feed water section:

The feed water is processed before the reforming process in order to avoid problems in the
reforming process due to contamination. The water purification system prepares the water for
the correct purity and removes locally used disinfectants from the feed water stream, such as
chlorine. The water purification system is included in the Hy.GEN 50 system and consists of, in
subsequent order, a sediment filter, a carbon block filter, a reverse osmosis (RO) unit and an
electro deionisation (EDI) module.

1.1 Hydrogen generation module

In the reformer module the natural gas/steam mixture is converted into a hydrogen rich stream
by means of steam reforming. The required steam is generated with an integrated steam
generator and the mixture is preheated by an internal recuperative heat exchanger. The
necessary heat is brought into the system, using an integrated burner that combusts the off-gas
coming from the VPSA through the off-gas section. The reforming process operates
approximately at 8,5 bar(g) at temperatures between 650 and 800 ºC.

1.2 Hydrogen cleaning module

VPSA section:
The VPSA-section is based on HyGear’s Q-cycle VPSA-technology. It is a Vacuum Pressure
Swing Adsorber that operates at the exit pressure of the reformer section. In a continuous cycle,
the hydrogen rich stream coming out of the reformer section is fed into the vessels, where all
contaminants are adsorbed.
In subsequent order the individual VPSA vessels are in the adsorption phase, where the
hydrogen rich stream enters the vessel and clean hydrogen exits the vessel.
When the vessel adsorbance material is saturated with contaminants, the system switches to
the following vessel, which has been cleaned and pre-pressurized beforehand. The saturated
VPSA vessel is cleaned with hydrogen and the contaminants are released by the adsorbance
material. The vacuum pump creates a pressure below atmosphere, which improves the
cleaning capacity. The off-gas (a mixture of H2, CH4, CO, CO2 and some other fractions) is all
going to the off-gas vessel. The Q-cycle VPSA-technology results in a continuous high purity
hydrogen stream.

Off-gas vessel section:

The off-gas vessel section contains a 900-litre stainless steel storage vessel where the off-gas
is collected. This vessel is used to equalize the pulsating off-gas stream from the VPSA into a
continuous stream, which is fed back into the burner of the reformer module. There it is utilized
to generate heat in the integrated burner.

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 1.3 Hydrogen buffer module

The hydrogen stream coming out of the VPSA is an intermittent flow due to the process
operating condition of a VPSA. In order to provide a steady flow of hydrogen to the customer,
the pure hydrogen stream is fed into a 900-litre stainless steel buffer vessel. The hydrogen is
stored at a maximum pressure of 7,5 bar(g) in a buffer of 4 Nm3 inside the system. The rest
fraction, all possible pollutants such as CO, is in total less than 10 vppm for 5.0 quality.

1.4 System control module

The entire system is managed with the control panel interface by a single start and stop signal.
The PLC Human Machine Interface (HMI) is part of this control panel interface. The PLC unit is
integrated in the electronics cabinet and is controlling the entire Hy.GEN 50 system. All the
essential process and sub-process parameters are monitored and controlled. Depending on the
level of clearance - access to control parameters may be restricted - most of the monitored
values and control parameters can be accessed via the PLC HMI display panel. Further the
trends of several monitored parameters are visualized by way of graphs in the HMI display.
Optional is to install an additional desktop PC for data acquisition and for graphic visualization
of several essential process and sub-process parameters. The desktop PC is connected to the
PLC through an ethernet converter based on the TCP/IP network protocol for data logging.
The desktop PC has no control functions.
With a remote access connection a secure tunnel to the PLC and optional desktop PC can be
opened. This enables remotely configuration, programming or debugging of the Hy.GEN 50
system.

1.5 Reformate Cooling Module

For correct functioning of the VPSA, the upstream VPSA reformate gas must first be cooled.
With ambient temperatures in the range from -20 to 10 C the reformate gas is cooled with the
internal system’s reformate cooler. The ambient ventilation air flows through the cooler and is
discharged by the ventilation fan. When ambient temperatures get close to 10 C, the ventilation
flow will increase up to the full capacity. The process waste heat is used to keep the system’s
cabinet temperature above zero in case of ambient frost conditions.
In the situation of ambient temperatures exceeding 10 C, the reformate gas will be mainly
cooled with the external dry cooler.
As a standard the dry cooler is installed next to the Hy.GEN 50 at ground level, see 3.2 (Area
for service). To reduce footprint it is optional to install the dry cooler on top of the Hy.GEN 50.
It is possible to fit the Hy.GEN 50 with an optional winter kit. The winter kit makes the Hy.GEN
50 suitable for installation in extreme cold climates, where temperatures drop below the -20 C
and can become as low as -40 C.

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 2.3 Utilities quality specifications

2.3.1 Natural gas

Natural gas as distributed around the world contains natural sulfur components or contains
traces of added odorants. The sulfur components can exist of Hydrogen sulphide (H2S),
Carbonyl sulphide (COS) and the worldwide used odorants THT or mercaptans. The odorants
are added to the gas for safety purposes, so leakage can easily be detected before a
dangerous situation occurs. Sulfur is harmful for the catalyst since it causes contamination and
degradation of the catalyst which results in performance decrease of the reformer. Therefore
the natural gas must be desulfurized before it is fed into the reformer.
Below are the typical specifications of the natural gas supply for the Hy.GEN 50 system.

Natural gas Specification Remark

Methane Main component, other listed components are impurities
Nitrogen < 15 vol %
Ethane < 5,1 vol %
Propane < 1,5 vol %
Iso-butane < 0,3 vol %
Normal-butane < 0,3 vol %
Iso-pentane < 0,14 vol %
Benzene < 0,1 vol %
Normal-pentane < 0,04 vol %
Hexanes plus < 0,06 vol %
Carbon dioxide (CO2) < 2,5 vol %
Oxygen (O2) < 0,1 vol %
Water (H2O) < 50 mg/m3
Total Sulfur (S) < 30 mg/m3 Value determines replacement time of desulf vessel content
H2S/Carbonyl sulphide (H2S + COS) (as S) < 5 mg/m3 Value determines replacement time of desulf vessel content
Mercaptans (RSH) (as S) < 6 mg/m3 Value determines replacement time of desulf vessel content
Tetrahydrothiofeen (THT) < 20 mg/m3 Value determines replacement time of desulf vessel content
Mercury < 0,001 ppb
Oil content < 1 mg/m3
Table 7: Typical specifications natural gas

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 2.3.2 Feed water

The Hy.GEN 50 system is equipped with a sediment filter, carbon block filter, reverse osmosis
system and an electro deionisation (EDI) module. The Hy.GEN 50 system feed water requires
pre-treated quality according to the specifications of Table 8.
Deviations from the listed water specifications results in scaling/fouling of the RO-unit
membrane and EDI module, which leads to component failure and a shorter service life.
Reformer catalyst damage can also be a possible consequence, when certain specifications are
widely exceeded.
Below are the typical quality specifications for the feed water input of the Hy.GEN 50 system.
HyGear recommends to install at all times a water softener system upstream of the Hy.GEN 50
system.

Feed water Specification Remark

Acidity 6 – 9,5 pH
Turbidity < 1 NTU
Silt Density Index <5
Total dissolved solids < 430 mg/l
Conductivity < 650 µS/cm
Conductivity equivalent < 1100 µS/cm Conductivity equivalent = conductivity + 2.79*CO2 + 1.94*SiO2
(Including CO2 + SiO2)
Total hardness < 2 ºdH
Total hardness (CaCO3) < 36 mg/l
Langier Sat Index (LSI) <0
Sulfates (as SO4) < 125 mg/l
Chloride < 125 mg/l
Sodium < 100 mg/l
Nitrates < 50 mg/l
Silicon (Si) < 10 mg/l
Silica (SiO2, H4SiO4 and (H2SiO3)n) < 15 mg/l
Total CO2 < 115 mg/l Combined CO2 and HCO3 -
Iron < 0,1 mg/l
Aluminium < 0,2 mg/l
Manganese < 50 µg/l
Chlorine < 0,2 ppm 0,2 ppm-> carbon filter life time of ½ year continuous
Hydrogen Sulphide (as S) < 0,03 ppb
Table 8: Typical quality specifications feed water

2.3.3 Instrument air

Typical specifications of the instrument air supply for the Hy.GEN 50 system are as follows:

Instrument Air Specification Remark

Quality class 3 ISO 8573-1
Particle size 5 µm
Pressure dew point -20 °C
Oil content 1 mg/m3
Concentration solid particles 5 mg/m3
Table 9: Typical specifications instrument air

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 2.3.4 Nitrogen

Typical specifications of the nitrogen supply for the Hy.GEN 50 system are as follows:

Nitrogen Specification Remark

Quality 2.7

Table 10: Typical specifications nitrogen

2.3.5 Hydrogen start-up

Typical specifications of the hydrogen supply for the Hy.GEN 50 system are as follows:

Hydrogen Specification Remark

Quality 3.5 Higher H2 start-up quality results in a faster production of
5.0 H2 quality
Table 11: Typical specifications hydrogen

2.3.6 Ventilation air

It is important to supply the ventilation air from a non-hazardous area. This implies that under all
circumstances the presence of possible flammable gasses should remain far below the lower
explosion limits. In case the ventilation air contains high concentrations of sand or dust, the
customer should install an upstream ventilation air filter. Typical specifications of the ventilation
air supply are as follows:.

Ventilation air Specification Remark

Hydrogen < 10 ppm Values > 62 ppm = system alarm & Values > 375 ppm = system shutdown1
Carbon monoxide < 5 ppm Values > 25 ppm = system alarm & Values > 150ppm = system shutdown
Silicone < 0,1 ppb Exceeding this value affects the functionality of the LEL detection system
Table 12: Typical specifications ventilation air

1
): Hydrogen intake is limited due to hydrogen cross sensitiveness of Hy.GEN 50 carbon monoxide detection sensors

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 2.4 Outputs quality specifications

2.4.1 Flue gas

Typical composition of the flue gas output for the Hy.GEN 50 system are as follows:

Flue gas Specification Remark

Composition (dry)
CO2 12,3%
O2 10,0%
N2 77,5%
NOX < 50ppm
CO < 90ppm
Table 13: Typical composition flue gas

2.4.2 Central vent

Typical composition of the central vent output for the Hy.GEN 50 system are as follows:

Central vent Specification Remark

Off-gas gas composition (dry) 1
CH4 27 % Composition percentages are average values with a continuous
CO 0,3 % hydrogen production of 43 Nm3/h H2. These percentages will deviate
CO2 52,7 % from the listed values for lower hydrogen production quantities.
H2 20 %
Table 14: Typical composition central vent

1
) These values are based on reformer feed of 100% methane (CH4).

2.4.3 Ventilation air discharge

Below are the typical specifications of the ventilation air output for the Hy.GEN 50 system.
During normal operating conditions the ventilation air output composition is similar to the
composition of the ventilation air input. Only when leakages occur inside the cabinet, the values
can get as high as the listed specification value.

Ventilation air Specification Remark

1
Hydrogen < 375 ppm Values > 375 ppm = system shutdown
Carbon monoxide < 150 ppm 1 Values > 150ppm = system shutdown
Methane < 20 % LEL 1 Values > 20% LEL = system shutdown
Table 15: Typical specifications central vent

1
): During normal operating conditions the air output composition is similar to the air input composition.
Only when leakages occur inside the cabinet, the values can get as high as the listed specification value.
When levels are exceeded the system shuts down and all valves will close preventing any further release.

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 3 System drawings

3.1 Connections

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 3.2 Area for service

The drawn area determines the minimal required distance between the Hy.GEN 50 system and
other objects in order to perform necessary service.

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 3.3 Short side 1 (cutaway system view)

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 3.4 Short side 2 (cutaway system view)

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 3.5 Long side 1 (cutaway system view)

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 3.6 Long side 2 (cutaway system view)

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 3.7 Dry cooler

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 3.8 Atex zone (IEC 60079-10-1) classification Hy.GEN 50 exterior

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