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Review Article

Hydrogen production with CO2 capture

Mari Voldsund*, Kristin Jordal, Rahul Anantharaman


SINTEF Energy Research, Sem Sælandsvei 11, NO-7465 Trondheim, Norway

article info abstract

Article history: In view of the abundance of fossil fuels, hydrogen production with CO2 capture could be a
Received 28 October 2015 key transition technology for moving in the direction of a sustainable hydrogen-using
Received in revised form society. An overview of technologies for hydrogen production from fossil fuels with CO2
23 December 2015 capture is provided in this paper: reforming or gasification with subsequent gas separation
Accepted 4 January 2016 by adsorption, absorption, membranes or cryogenic/low-temperature separation; process
Available online 15 February 2016 routes with integrated syngas production and gas separation by wateregas shift mem-
brane reactors, reformer membrane reactors, sorption-enhanced wateregas shift and
Keywords: sorption-enhanced reforming; and processes utilizing the concept of chemical looping.
CO2 capture Furthermore, purity requirements for the produced CO2 and hydrogen are reviewed. Few
Hydrogen production technologies exist that can produce both high-purity hydrogen and CO2 at transport quality
Hydrogen use simultaneously, and the few possible approaches are maximum on the pilot stage. Pro-
Gas separation ducing hydrogen from fossil fuels, while capturing the CO2 for transport and storage is
therefore a matter of matching hydrogen and CO2 separation technologies in a best
possible manner, taking into account the planned transport option for the CO2 and the way
in which the hydrogen will be used. Hydrogen production with CO2 capture can potentially
lead to large CO2 emission reductions in eg. transport sector.
Copyright © 2016, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights
reserved.

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4971
1.1. Global background: fossil-fuel based hydrogen production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4971
1.2. Technology background: process routes for hydrogen production with CO2 capture . . . . . . . . . . . . . . . . . . . . . . . . 4972
1.3. Paper aim and strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4973
2. Syngas production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4973
2.1. Steam reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4973
2.1.1. Steamemethane reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4973
2.1.2. Partial oxidation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4973
2.1.3. Autothermal reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4974

* Corresponding author.
E-mail addresses: mari.voldsund@sintef.no (M. Voldsund), kristin.jordal@sintef.no (K. Jordal), rahul.anantharaman@sintef.no
(R. Anantharaman).
http://dx.doi.org/10.1016/j.ijhydene.2016.01.009
0360-3199/Copyright © 2016, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.
4970 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 1 ( 2 0 1 6 ) 4 9 6 9 e4 9 9 2

2.2. Gasification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4974


2.3. Wateregas shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4974
2.4. Typical syngas compositions and conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4974
3. Separation technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4975
3.1. Adsorption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4975
3.1.1. PSA for hydrogen purification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4975
3.1.2. PSA for CO2 capture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4976
3.2. Absorption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4976
3.3. Membrane separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4977
3.3.1. Hydrogen selective membranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4977
3.3.2. CO2 selective membranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4977
3.4. Cryogenic/low-temperature separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4977
3.4.1. Cryogenic separation of hydrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4978
3.4.2. Low-temperature separation of CO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4978
3.5. Technology performance summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4979
4. Advanced hydrogen production with CO2 capture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4979
4.1. Integrated syngas production and gas separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4979
4.1.1. Membrane reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4979
4.1.2. Sorption-enhanced hydrogen production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4981
4.2. Chemical looping hydrogen production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4982
4.2.1. Syngas chemical looping process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4982
4.2.2. Direct chemical looping gasification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4983
4.3. Technology performance summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4983
5. CO2 and hydrogen product purity requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4983
5.1. CO2 purity requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4983
5.2. Hydrogen purity requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4984
6. Large-scale plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4985
6.1. Ammonia synthesis with CO2 capture by absorption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4985
6.2. Hydrogen production for refineries with CO2 capture by absorption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4985
6.3. Hydrogen production for refineries with CO2 capture by VSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4985
7. Selection of process route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4985
7.1. Retrofit versus new plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4985
7.2. Process intensification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4986
7.3. Process integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4986
7.4. Combination of technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4986
7.5. Trade-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4987
8. Outlook on production and use of hydrogen in a CCS context . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4987
8.1. Emission reductions in the transport sector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4987
8.2. Use of hydrogen in industry and power generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4987
8.3. CO2 emissions between hydrogen production and end user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4988
9. Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4988
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4988
Supplementary data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4988
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4988
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industry without resorting to hydrogen may be hard to ach-


Abbreviations ieve” [2].
The current global hydrogen production is approximately
ATR Autothermal reforming
7.2 EJ per year. It is largely fossil-fuel based, resulting in
CCS CO2 capture and storage
approximately 500 Mt CO2 per year [3]. The shares of the
CLC Chemical looping combustion
various production methods of hydrogen globally are shown
EOR Enhanced oil recovery
in Fig. 1. Conversion of fossil fuels is responsible for 96%, while
ESA Electric swing adsorption
electrolysis of water is responsible for the remaining 4%.
ETP Energy Technology Perspectives
Natural gas steam reforming holds the largest share of the
FCEV Fuel cell electric vehicle
production from hydrocarbon sources, the second largest part
HDV Heavy duty vehicle
is oil-based, and the remaining part is derived from coal
HHV Higher heating value
gasification.
HT High-temperature
The hydrogen use by sector in 2013 compared to projected
IEA International Energy Agency
use in 2050 in IEAs standard and high-hydrogen 2DSs are
IGCC Integrated gasification combined cycle
shown in Fig. 2. In the standard 2DS, the deployment of fuel
LDV Light duty vehicle
cell electric vehicles (FCEVs) in the passenger light duty ve-
LT Low-temperature
hicles (LDVs) sector begins in earnest in 2025. By 2050 FCEVs
MDEA Methyl diethanolamine
have a share of 13% of the total passenger LDV fleet and 7% of
MEA Monoethanolamine
the total truck stock. In the high-hydrogen 2DS, FCEVs are
MOF Metal-organic framework
PEM Proton exchange membrane
POX Partial oxidation
PSA Pressure swing adsorption
S/C Steam-carbon
SE-SMR Sorption-enhanced steamemethane reformer
SE-WGS Sorption-enhanced wateregas shift
SMR Steamemethane reforming
SMR-MR Steamemethane reformer membrane reactor
TEA Triethanolamine
TSA Temperature swing adsorption
VSA Vacuum swing adsorption
WGS Wateregas shift
WGS-MR Wateregas shift membrane reactor
2DS 2 ! C Scenario
Fig. 1 e Shares of production methods for hydrogen
worldwide [3].

Introduction

Global background: fossil-fuel based hydrogen production

The International Energy Agency (IEA) states in Energy Tech-


nology Perspectives (ETP) 2015 that in order to limit global
temperature increase to 2 ! C (the 2 ! C Scenario e 2DS), energy-
and process-related CO2 emissions should be cut by almost
60% by 2050 compared to 2012. It mentions using hydrogen
based on low-carbon sources as energy carrier as an impor-
tant option to reduce CO2 emissions. Furthermore, it states
that hydrogen production is one of the “sweet spots” for CCS e
it is one of the sectors where the gap is smallest between
current CCS technology costs and the willingness of govern-
ments and firms to invest in climate change mitigation [1].
In ETP 2012 the potential role of hydrogen was studied in
particular by developing two alternative 2DSs: the 2DS high- Fig. 2 e Global hydrogen consumption by sector in EJ in
hydrogen and the 2DS no-hydrogen. It was stated that hydrogen 2013 and anticipated future use in 2050 in the IEA standard
may become especially important in the very long term, and 2DS and high-hydrogen 2DS (see Supplementary
that “completely eliminating fossil fuels in transport and Information for background data).
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commercially introduced by 2020 and the number of vehicles production covered by fossil sources with CCS would be
by 2050 is doubled compared to the standard 2DS. Hydrogen considerable.
use in industry and buildings is not assumed to start before
2050 in the standard 2DS. In the high-hydrogen 2DS, Technology background: process routes for hydrogen
hydrogen-based steel making and CO2-free hydrogen as production with CO2 capture
feedstock and energy carrier in the chemical and petro-
chemical sector will play a role in the industry, and fuel-cell With present commercial hydrogen production technologies,
co-generation units will be taken into use in buildings [2]. fossil fuel sources are first converted to syngas. The syngas is
The development and market introduction of FCEVs ap- typically produced by gasification or reforming, eg. steame-
pears to be accelerating. Toyota has launched a FCEV model in methane reforming (SMR) or autothermal reforming (ATR),
Japan in 2014, Hyundai is planning to begin the sale of FCEVs followed by wateregas shift (WGS). The shifted syngas con-
in the near future and has had a model available for lease sists mainly of hydrogen and CO2, but also some unconverted
since summer 2014, and Honda announced plans to launch its or partly converted combustible components like CH4 and CO,
next generation FCEVs in 2016 [3]. The demand for hydrogen and possibly components like H2S, N2 and/or Ar. The CO2 and
in the transport sector could increase faster that predicted by the other impurities are separated from the hydrogen in a
IEA even in the high-hydrogen scenario, requiring an even hydrogen purification unit.
higher amount of hydrogen production. For a hydrogen production process with CO2 capture, the
On a long term, large-scale hydrogen production by elec- gas separation part following the syngas production must be
trolysis of water with abundant electric power from renew- extended. This is most easily done by including an additional
able sources would be preferable. The hydrogen would be separation unit. The objective is now to obtain high-purity
continuously consumed as fuel for automotive and stationary hydrogen and CO2 of sufficiently high purity for transport
fuel cells and as feedstock in the industry. In periods with and storage. This would give three resulting process streams:
excess renewable power, hydrogen could be stored, giving the one stream with purified hydrogen, one with purified CO2, and
possibility to provide load-following electric power an off-gas containing some hydrogen, CO2, CO, CH4, N2, etc.
production. A general hydrogen production route with CO2 capture is
On a shorter term, with increasing but still insufficient shown in Fig. 3. In the case of gasification or ATR, fuel is
supply of renewable energy, hydrogen production from fossil oxidized inside the reactor providing heat (the reactor is
fuels with CO2 capture and storage (CCS) may prove to be an internally heated) whereas for SMR, heating is provided by
enabler for low CO2-emission hydrogen production. IEA pre- burning fuel in a furnace (the reactor is externally heated). For
sents in their Technology Roadmap for Hydrogen and Fuel the latter case, a separate stream of fossil fuel is provided to
Cells [3] suggested pathways to meet the demand for the reforming furnace, and flue gas is produced. If CO2 in this
hydrogen within the high-hydrogen 2DS at lowest cost case is captured only from the syngas, around 60% of the CO2
(assuming carbon prices for emissions) for US, EU 4 (Germany, from the overall process can be captured. For a higher CO2
Italy, France, UK) and Japan. In these scenarios renewable capture ratio, a separate CO2 capture unit is required for the
electricity and biomass account for 12e38% of the hydrogen flue gas (post-combustion capture).
production in 2050, while fossil sources with CCS account for The currently most used technology for hydrogen purifi-
58e81%. The share of renewable electricity may prove to be cation is pressure swing adsorption (PSA), while the most
higher in 2050 than suggested by IEA, and this would be the mature technology for CO2 capture is absorption with sol-
preferred scenario. However, even if the shares of renewables vents. Alternatively, novel separation technologies such as
were doubled compared to the IEA pathways, the hydrogen different kinds of membranes and sorbents can be used, or

Fig. 3 e The presently most mature route for hydrogen production from fossil sources with CO2 capture. Solid black lines
represent gasification or autothermal reforming processes, while dashed black lines represents additional streams and
units for the steamemethane reforming process. The preferred sequence of the CO2 capture and hydrogen purification units
in the gas separation part depends on the selected technologies.
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low-temperature/cryogenic separation. Furthermore, requirements for hydrogen and CO2 purity are listed. There-
advanced technologies for hydrogen production with CO2 after, a review of current large-scale plants are given. This is
capture are under development, such as membrane reactors, followed by a discussion on the selection of process route,
sorption-enhanced hydrogen production, and chemical loop- before an outlook on production and use of hydrogen in a CCS
ing hydrogen production. The technologies for membrane context is given.
reactors and sorption-enhanced reforming and WGS are
developed in the context of process intensification: the syngas
production and gas separation steps are combined to get more
Syngas production
compact and efficient processes where the equilibrium-
limited reactions in the syngas production step are shifted
A first step in the generation of hydrogen from fossil fuels
towards the product side by continuously removing one of the
(solid, liquid or gaseous) is the production of shifted syngas
products. Chemical looping hydrogen production is developed
(largely consisting of CO2 and H2). Today, syngas is also pro-
in the context of CO2 capture.
duced in large scale as a first step in the synthesis of chemicals
like ammonia and methanol. Different industrial options are
Paper aim and strategy
well known, and only briefly described below.

The aim of this paper is to provide a general overview and


status of different technology options for fossil-fuel based Steam reforming
hydrogen production for different hydrogen users with CO2
capture. This includes technologies that are commercially In steam reforming, gas or liquid fossil fuel is converted to
available today, and technologies that are in an R&D phase. syngas. Important processes are SMR, partial oxidation and
The literature is replete with papers on hydrogen produc- ATR.
tion with CO2 capture focussing on specific production routes
and technologies. As regards review papers giving an over- Steamemethane reforming
view of several technologies, a review was made in 2006 by In SMR, steam and methane react to yield hydrogen and car-
Damen et al. [4] with the purpose to compare the cost of bon monoxide in an equilibrium-limited, highly endothermic
hydrogen and electricity production with CO2 capture for reaction:
different technology options. The main focus was on absorp-
CH4 þ H2 O#CO þ 3H2 DHrx ¼ 206 kJ=mol (1)
tion and membrane capture technologies. Further, a tech-
nology review on hydrogen production for chemical and The reaction is normally carried out at temperatures of
petrochemical industries was provided by Ritter and Ebner in 500e900 ! C, pressures of 20e35 atm and steam-to-carbon (S/C)
2007 [5]. This review included technologies such as membrane ratios of 2.5e3.0 [5,9]. High conversion is favoured by high
reactors and sorption enhanced reaction processes, but the temperature, low pressure and high S/C ratio (which also
perspective of CO2 capture was not incorporated. An extensive limits carbon deposition) [9]. However, low S/C ratio is
and in-depth description of syngas generation, hydrogen preferred from an energy efficiency and economic point of
production and purification technologies was provided in 2010 view. In modern plants, high temperatures (>900 ! C) are
in the book edited by Liu et al. [6], where CO2 capture is briefly possible, allowing S/C ratios below 2.5 [10].
mentioned. Kenarsari et al. [7] provided in 2013 a review on SMR is normally performed in externally heated packed
CO2 capture technologies with a section about pre- bed reactors, often with a Ni-based catalyst which has suffi-
combustion capture, while Jansen et al. [8] presented in 2015 cient activity and a low cost [9]. The catalyst is sensitive to H2S
a dedicated review on the topic pre-combustion capture. poisoning, so if there are considerable amounts of sulphur in
Many of the pre-combustion technologies presented are the natural gas, this has to be removed in a desulphurisation
relevant for hydrogen production with CO2 capture. However, unit prior to the SMR.
the focus is on power production, where the produced If the feed contains ethane and other heavier hydrocar-
hydrogen does not have to be of high purity. No recent and bons, a pre-reformer can be used upstream the reformer. A
comprehensive review has to the authors' knowledge been pre-reformer converts the heavier hydrocarbons into
provided that gives an overview on all relevant technologies methane, and also reforms some of the methane into CO and
for production of hydrogen with CO2 capture. The present hydrogen. It operates at lower temperatures than the
paper aims at filling this gap. reformer: around 400e500 ! C [5].
CO2 capture as well as hydrogen production from fossil
fuels are vast areas where tremendous research efforts are Partial oxidation
being made. The primary strategy in this paper for assembling Partial oxidation (POX) of hydrocarbons is a method for pro-
knowledge on technology performance and status has there- ducing hydrogen from heavy hydrocarbons such as diesel fuel
fore been to go through recent review papers on the various and residual oil. In principle, any hydrocarbon feedstock that
technologies, and to complement the findings with additional can be either compressed or pumped may be used for syngas
knowledge from relevant research papers. production with this technology. The reaction occurs when a
The paper starts with an introduction to syngas produc- fuel is partially burnt with a substoichiometric amount of air
tion, and a review of the relevant separation technologies and in a reformer. Partial oxidation is an exothermic process and
advanced technologies for hydrogen production with CO2 can be performed both with and without catalyst. The general
capture. Then current standards and knowledge on reaction equation is:
4974 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 1 ( 2 0 1 6 ) 4 9 6 9 e4 9 9 2

of CO to CO2, and because the hydrogen yield is maximised.


Cm Hn þ m=2O2 #m CO þ n=2H2 (2)
The reaction is equilibrium-limited and slightly exothermic:
Large-scale uncatalysed reactors typically operate at tem-
peratures in the range of 1150e1500 ! C and pressures between CO þ H2 O#CO2 þ H2 DHrx ¼ $41 kJ=mol (8)
25 and 80 bar [5,11]. For the catalytic POX process operating WGS conversion is favoured at low temperatures, while
temperatures and pressures are lower (temperature between reaction kinetics are favoured at high temperatures [13].
780 and 900 ! C and pressure between 25 and 35 atm). Pure or Similar to the SMR, a high S/C ratio gives high CO conversion,
enriched oxygen supplied by an oxygen plant is commonly but results in an efficiency penalty. Since the net amount of
used, in order to avoid processing nitrogen downstream. moles does not increase in the reaction, the total pressure
However, for ammonia production some nitrogen is desirable, does not influence the CO conversion. However, a high pres-
and the oxygen can be supplied as air [5]. sure gives a higher reaction rate [14].
The WGS reaction is often conducted in at least two stages:
Autothermal reforming first a high temperature step (HT WGS) at 320e360 ! C and
ATR is the combination of non-catalytic POX and SMR. 10e60 bar where fast reaction is favoured, and the catalyst bed
Methane is reacted with oxygen and steam in a single volume is therefore minimized; then a low temperature step
chamber: (LT WGS) at 190e250 ! C and 10e40 bar where a high conver-
sion is favoured. This allows a smaller adiabatic temperature
CH4 þ 1=2H2 O þ 1=4O2 #CO þ 5=2H2 DHrx ¼ 84 kJ=mol (3)
rise and a better steam management, at the same time as the
In principle, the heat required for the endothermic SMR amount of catalyst is minimised and high conversion is ob-
reaction is provided by the exothermic POX reaction. The tained [14].
temperature of the reaction, and the H2/CO ratio in the prod- The reaction may be performed both with H2S present
uct can be controlled by varying the steam and oxygen (sour WGS) and without (sweet WGS). For the case of sour
amounts. The reaction is normally carried out with tempera- WGS, a cobalt-molybdenum catalyst is used. For sweet WGS,
tures in the range of 900e1150 ! C, and ATR reformer pressures the HT WGS is often carried out with a Fe-based catalyst, while
can be between 1 and 80 bar [11]. As for partial oxidation, the the LT WGS is often carried out with a Cu-based catalyst [14].
oxygen may be provided in pure form (O2-blown ATR) or as air After WGS, the syngas is usually cooled and flashed to
(air-blown ATR), depending on whether the syngas will be remove water.
used in ammonia synthesis or not.

Typical syngas compositions and conditions


Gasification
The composition, temperature and pressure of the resulting
Solid fuels like coal or biomass can be converted to syngas by
syngas depends on factors such as the selected reforming or
gasification. In this process, the fuel is reacted with oxygen
gasification type, the composition of the fuel that has been
and steam at high temperature and pressure. Some of the
used, S/C ratio, the degree and conditions of the shift reaction,
reactions taking place are:
and the purity and flow of the oxygen feed (if used). In general,
C þ H2 O#CO þ H2 DHrx ¼ 131 kJ=mol (4) syngas originating from natural gas has higher hydrogen
levels and lower CO2 levels than coal derived syngas, and for
C þ O2 #CO2 DHrx ¼ $394 kJ=mol (5) syngas from air-blown ATR the level of nitrogen is significant.
Natural gas derived syngas has very low levels of sulfur
compounds, because most sulfur is removed before the
C þ 1=2O2 #CO DHrx ¼ $111 kJ=mol (6)
reformer to prevent catalyst poisoning, while coal derived
syngas typically contains more sulfur. Shifted syngas com-
C þ CO2 #2 CO DHrx ¼ 172 kJ=mol (7)
positions from some literature sources are given in Table 1.
Most commercial gasifiers are entrained-flow gasifiers, and
the most well known examples are GE and Shell Gasifiers. In a
GE gasification system, the gasification temperatures are in Table 1 e Shifted syngas composition given in mol% from
the range 1350e1500 ! C. The pressure can be as high as different feedstocks and reforming/gasification. The
100 bar, but is often selected based on the purpose of the gas syngas is normally saturated with water, but all
product, for instance 85e100 bar in the ammonia industry and compositions are converted to dry basis. Where not
specified in the source, % is assumed to be mol%.
60e70 bar in the methanol industry. Shell gasifiers typically
operates at pressures of 20e40 bar and temperatures of SMR þ WGS Air-blown Coal
[5,15] ATR gasification
1440e1600 ! C [12].
þ WGS [16,17] þ WGS [18e22]
H2 70e80 44e49 54e57
Wateregas shift CO2 15e25 17 38e44
CO 0.5e3 0.52e0.58 0.6e1.7
After reforming or gasification, the produced CO is typically N2 trace 33e38 1.0e4.8
reacted with steam to produce CO2 and additional hydrogen in Ar 0.39e0.45 0.47e0.90
the WGS reaction. This reaction is particularly important for CH4 3e6 0.07e0.09 %1.33
H2S %0.06
hydrogen production with CO2 capture, due to the conversion
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 1 ( 2 0 1 6 ) 4 9 6 9 e4 9 9 2 4975

relevant, because the syngas is at elevated pressure allowing


for pressure swing with limited energy penalty.

PSA for hydrogen purification


PSA is the currently most used technology for hydrogen pu-
rification with the possibility to obtain very pure hydrogen
(sometimes exceeding 99.9999 mol% [15]). The technology has
been used in hydrogen plants since the early 1980s [5]. Thor-
ough overviews of the topic are given by Ritter and Ebner [5]
and Sircar and Golden [15].
When PSA is applied to purify hydrogen from syngas, the
syngas is sent through an adsorbent column at high pressure,
where impurities are adsorbed while hydrogen passes
Fig. 4 e The concept of pressure swing adsorption e through with very limited adsorption. When the adsorbent is
adsorption and desorption of impurities. saturated, it is regenerated by lowering the pressure and
purging with hydrogen. The adsorption and desorption steps
are illustrated in Fig. 4.
Separation technologies Several columns are typically operated simultaneously
(Fig. 5), with adsorption, depressurisation, purge and pres-
After the production of shifted syngas, hydrogen and CO2 have surisation steps shifted in time. The hydrogen used in a purge
to be separated from the other components and purified. The step is supplied from another column that is in a depressur-
relevant separation technologies for hydrogen production isation step [15]. The resulting process is semi-continuous,
with CO2 capture are adsorption, absorption, membranes and and produces a high-purity hydrogen stream, and an off-gas
cryogenic/low temperature processes. containing the CO2, other impurities and some hydrogen.
For hydrogen purification, columns with multiple adsor-
Adsorption bents (layered beds) are normally used. Typical adsorbents
include silica gel, alumina, activated carbon, and zeolite, and
Adsorption is a physical process where molecules fix them- they have different relative strength of adsorption to different
selves on the surface of adsorbents (usually solid materials). components [5,23]. Although the method is well established,
Molecules have different affinities for various types of adsor- there is still room for optimisation of adsorbent material. New
bents, and this phenomenon can be used to purify gases. For types of adsorbent are under development, such as metal-
the purpose of hydrogen purification multiple types of ad- organic frameworks (MOFs) [24,25].
sorbents can be selected so that all types of impurities are PSA units are typically operated at ambient temperature
adsorbed and hydrogen passes through with very limited (adsorption is promoted at low temperature) and feed pres-
adsorption. For the purpose of CO2 capture, adsorbents that sure of 20e60 atm [5]. The hydrogen product is produced at
selectively adsorb CO2 from a gas mixture can be used. slightly lower pressure than the feed (typically with a pressure
Several types of adsorption processes exist, such as pres- drop of less than 1 bar) and the PSA off-gas is delivered at low
sure swing adsorption (PSA), temperature swing adsorption pressure, typically 1.1e1.7 atm [15]. A variation of PSA is
(TSA) or electric swing adsorption (ESA). For the purpose of vacuum swing adsorption (VSA), where pressure is reduced
hydrogen and CO2 separation from syngas PSA is most below atmospheric pressure with vacuum pumps.

Fig. 5 e Flow diagram for a multiple column PSA process.


4976 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 1 ( 2 0 1 6 ) 4 9 6 9 e4 9 9 2

PSA technology can produce 98e99.9999þ mol% hydrogen


with a hydrogen recovery of 60e95%, depending on feed gas
composition [5,15]. PSA units can be adjusted to provide very
low levels of CO, CO2 and CH4 in the hydrogen while they will
have more difficulty retaining argon, oxygen and nitrogen.
Furthermore, higher purity levels require higher adsorbent
volumes and result in lower hydrogen yield [23]. In standard
plants without CO2 capture, the CO2-rich off-gas is often used
as fuel due to the content of combustible components. It can
be observed that for transport and storage of the CO2, the PSA
unit is not sufficient, and another separation unit has to be
added to the process.
Fig. 6 e Principle of CO2 absorption from syngas.
PSA for CO2 capture
Adsorption can be used to capture and purify CO2 from other
gases with a CO2 selective adsorbent. Air Products and Liquid solvents can be divided into chemical and physical
Chemicals patented already in 1979 a PSA process for pro- solvents. Chemical solvents react with CO2 and require a
duction of high-purity hydrogen and CO2 [26]. This process considerable amount of heat for regeneration [36]. They offer
consists in principle of two steps: first six parallel adsorbent fast reaction rates, meaning small plant sizes [37]. Typical
beds with activated carbon selectively removes wet CO2, chemical solvents are aqueous solutions of amines such as
before three parallel adsorbent beds with zeolites removes MEA, TEA and MDEA, or aqueous solution of hot potassium
CH4, CO, N2, and the remaining CO2 from the hydrogen [15,27]. carbonate (eg. the Benfield process) [37,38]. Physical solvents
They have since 2013 run a demonstration plant where they dissolve CO2, and are regenerated with reduced pressure and/
have retrofitted an existing hydrogen production facility by or increased temperature, requiring less heat than chemical
adding a VSA unit that captures wet CO2, between the already solvents [34,36]. They commonly allow combined CO2/H2S
existing SMR and PSA units. More than 90% of the CO2 is removal [39]. Typical technologies utilising physical solvents
captured with purity greater than 97% (after compression and are the Rectisol®, Selexol™, and Purisol® technologies [34].
drying) from a syngas containing >15% CO2 [28e31]. The absorption capacity of chemical solvents is relatively
Alternative process set-ups have been patented but not high at low CO2 partial pressures. It increases with the CO2
realized in large-scale. Krishnamurthy et al. [32] suggest a partial pressure, but at a certain point it begins to saturate.
process where a CO2 PSA step is performed after the hydrogen The absorption capacity of physical solvents is lower than for
purification PSA step, thus eliminating the impact of any chemical solvents at low CO2 partial pressures, but increases
ingress of air in the CO2 PSA step on the hydrogen purity. linearly with CO2 partial pressure according to Henry's law.
Couche [33] suggests a process where a single PSA step con- Chemical solvents are therefore preferred at low CO2 partial
sisting of a set of parallel adsorption columns produces one pressures while physical solvents are preferred at high CO2
stream with purified hydrogen, one stream with wet CO2 and partial pressures [40].
one stream with off-gas with a mixture of hydrogen, CO2 and For CO2 capture from syngas various solvents may be
other components. The two latter streams are produced dur- optimal depending on the syngas conditions and the targeted
ing regeneration of the columns at different pressure levels. purity of the product. In CO2 capture from syngas in IGCC
This concept is a rare example on hydrogen- and CO2 purifi- processes, there have been several studies comparing sol-
cation combined in one process unit. vents with different conclusions (process simulation studies
such as [40,41], or pilot testing such as the Eagle project [42]).
Absorption In the Puertollano demonstration project activated MDEA was
used [43], while the Selexol process is selected in the Kemper
Gas separation by absorption is carried out industrially by County project [44]. The conclusions may be different when
bringing the gas in contact with a liquid solvent in a scrubber hydrogen of high purity is targeted. For instance, Rectisol is
column, where certain impurities are absorbed. The rich sol- the technology that can give the deepest purification. It has
vent is then heated and/or depressurised and sent to a the ability to purify coal gasification syngas to 0.1 ppm total
regeneration column which produces one stream with the sulfur and CO2 in ppm range [8], [45].
absorbed components, and one with lean solvent that is sent The purity of the produced CO2 stream also depends on the
back to the scrubber column. The principle is shown for CO2 syngas and on the selected technology. For instance, MDEA is
absorption from syngas in Fig. 6. shown to be able to capture CO2 at >99% purity with 95% re-
CO2 absorption is a commercially mature technology, covery rate from ATR syngas [16]. Rectisol can capture CO2 at
frequently used in natural gas sweetening (first done in the 95% (standard) or >98.5% (advanced) purity. Very high recov-
1930s with TEA [34]). It was commonly used for purification in ery rates can be achieved, while for IGCC applications CO2
hydrogen plants prior to 1980 when PSA which could produce recovery rates of typically 90e97% are reported. Selexol can
high-purity hydrogen for the same costs became commer- capture CO2 at 98e99.7% purity. All these solvents capture
cially available [5,35]. The technology is still commonly used sulfur components together with CO2, but it is possible to
for purification of hydrogen in ammonia plants with a sub- modify some of the processes to produce CO2 and sulfur as
sequent methanator [5]. separate streams [46]. On overall it can be observed that
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 1 ( 2 0 1 6 ) 4 9 6 9 e4 9 9 2 4977

absorption technology can produce CO2 at high purity. CO2 mechanical stability: very thin membrane materials are
recovery rates can be very high, but impurities such as CO and developed to increase the hydrogen flux, but these materials
CH4 are not removed. The hydrogen is therefore produced at must withstand the pressure differential over the membrane.
lower purity. Another major challenge is the chemical stability: the mate-
rials are sensitive to poisoning by components such as CO and
Membrane separation H2S. Furthermore, the production costs are high due to the use
of precious metals [50]. Palladium-based membranes are
Membranes are selective barriers that are ideal for separation available on the market, but these are relatively thick, and
purposes because they let certain components pass through therefore expensive and with low hydrogen permeance
more easily than others. The part of the feed that passes [47,50]. Dense ceramic membranes have also very high
through the membrane is denoted permeate while the part that selectivity, but they have generally lower flux than the
does not pass through is denoted retentate. Characteristics metallic membranes, and they are also sensitive to poisoning
essential for membranes are (i) high selectivity, (ii) high flux, [50]. Microporous membranes have lower selectivities, but
(iii) low cost, (iv) high mechanical stability and (v) high they are cheaper and have greater chemical stability (although
chemical stability. The transport of molecules through the water vapour can affect performance) [53]. So far, there is no
membrane is driven by difference in partial pressures over the clear winner among the high-temperature membranes and
membrane, and depending on the process there may be a none are commercial on large scale [53].
demand for compression power. In overall, high-temperature hydrogen membranes are
For hydrogen production with CO2 capture, both hydrogen available, and they are continuously improved. The main
and CO2 selective membranes are relevant. Hydrogen selec- challenges for large-scale industrial application are fabrica-
tive membranes produce a permeate consisting of high-purity tion reproducibility, material costs, and the chemical and
hydrogen (although the purity depends on membrane type) at mechanical stability [47,49,50]. However, the technology is
low pressure, and a retentate with impure CO2 at higher under transition to pilot stage. Kinetics Technologies have
pressure. CO2 selective membranes typically produce a CO2 tested three types of commercial membranes in a 20 Nm3/h
enriched permeate at low pressure, and a CO2 depleted hydrogen production plant for over 1300 h, and demonstrated
retentate at high pressure. that all three membranes showed operational stability for
operation with SMR syngas [54]. Reinertsen and SINTEF are
Hydrogen selective membranes presently in the beginning of a project where they aim for up-
The most mature type of hydrogen selective membranes is scaling hydrogen purification with a Pd-based membrane in a
polymeric membranes. They have operating temperatures below pilot producing 25e100 Nm3/h hydrogen [55].
100 ! C, and have been used for hydrogen recovery from low-
temperature process streams for many years [5,47,48]. They CO2 selective membranes
can withstand high pressure drops and they are relatively It is challenging to separate CO2 selectively from mixtures
cheap [49]. However, such membranes have relatively low with hydrogen, since the CO2 molecule is much larger than the
hydrogen selectivity and hydrogen flux, limited mechanical hydrogen molecule. However, several membrane types exist:
strength, high sensitivity to swelling and compaction and they polymeric CO2 selective membranes based on either solution-
are vulnerable for poisoning from components such as HCl, diffusion mechanism (the solution effect must dominate
SOx and CO [49,50]. Their poor selectivity of hydrogen against over diffusion), or facilitated transport mechanism [53]; mixed
CO2 is a large drawback for use in CO2 capture [51]. This is also matrix membranes, which consist of inorganic particles
a drawback for production of high-purity hydrogen. dispersed uniformly in a polymer matrix [56]; and porous
High-temperature hydrogen selective membranes are under inorganic membranes that are CO2 selective either by surface
development and subject to extensive research. Such mem- diffusion or capillary condensation. One interesting mem-
branes have high operating temperatures, and can be divided brane type under development is dual-phase membranes con-
into metallic membranes (300e700 ! C), microporous ceramic sisting of a molten carbonate phase and metal or ceramic
membranes (200e600 ! C), porous carbon membranes (500e900 ! C) phase, that show great potential for high temperature opera-
and dense ceramic membranes (600e900 ! C) [50]. These mem- tion [57], [58].
branes have the potential to offer higher hydrogen flux and There are currently commercial membranes on the market
selectivity compared to polymeric membranes [47]. However, that can separate CO2 from hydrogen, albeit with low selec-
they are currently too expensive for industrial use. For bulk tivity and with low operating temperature [53]. As stated by
separation of hydrogen after WGS, the membranes with Scholes et al. [53] (in the context of CO2 capture from IGCC),
operating temperatures in the range 200e400 ! C are of highest CO2 selective membranes are significantly less advanced than
interest. The membranes with higher operating temperatures hydrogen selective membranes, and considerable more
are more relevant for separation after SMR, or in a SMR-MR. research is required before they can be applied. At the current
Many reviews on hydrogen membranes are available, such state, such membranes can be used for CO2 enrichment, but
as [5,47e50,52]. CO2 at transport quality is not achieved directly.
The most widely studied membranes for hydrogen sepa-
ration are metallic membranes, most often made from palla- Cryogenic/low-temperature separation
dium or palladium alloys. Their theoretical selectivity is
infinite, and membranes giving hydrogen purities of In cryogenic or low-temperature separation gas is cooled, and
99e99.995% have been developed. One major challenge is the differences in boiling point is used in order to separate
4978 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 1 ( 2 0 1 6 ) 4 9 6 9 e4 9 9 2

different chemical components. For separation of hydrogen, 90e115 bar, before it is cooled to around $55 ! C with a multi-
the gas mixture is cooled to cryogenic temperatures stream process-to-process heat exchanger, and a cascade
(<$150 ! C). Contaminant gases are condensed at different propane and ethane refrigeration cycle. CO2 is then
temperature levels, while the hydrogen remains in gas phase. condensed out from the syngas in a separator. In order to
For separation of CO2, the gas mixture is cooled below the obtain a high CO2 purity and avoid loss of hydrogen, the ob-
boiling point of CO2 at the given pressure (above the CO2 triple tained CO2 is purified with a flash separator at lower pressure
point at 5.2 bar and $56.6 ! C), and the CO2 is condensed from and higher temperature. In the process described, expanders
lighter gaseous species. are used to recover power from the hydrogen-rich process
stream. Process simulations have shown that CO2 purities in
Cryogenic separation of hydrogen the range of 99.7e99.9 mol% can be obtained.
Cryogenic separation processes can be used to produce Berstad et al. [63] provide a review on the applications and
moderately pure hydrogen from syngas, and are in some potential of low-temperature separation, showing that the
existing syngas plants used to adjust the composition of process shows promising potential and competitive energy
syngas for a chemical feedstock unit [5]. In ammonia pro- figures for capture from syngas (in particular coal-derived).
ductioncryogenic separation is often integrated in the purge The CO2 separation and compression work decreases with
gas recovery loop from the back to the front end of the increasing CO2 concentration in the feed. CO2 recovery of
ammonia unit [59]. It is also used in refineries to recover 85e90% may be obtained. Alternative low-temperature sepa-
hydrogen from gas streams vented from hydrocracking or ration principles are capture by condensed rotational sepa-
hydrotreating operations [60]. One of the earliest processes for ration [64] and distillation [20].
cryogenic separation of hydrogen from syngas is the Linde- An advantage with low-temperature separation is that the
Bronn process [59,61]. Cryogenic separation is generally not captured CO2 is in liquid state and can be pressurized for
used as the main separation system in hydrogen and transport by pumping at low energy cost [20]. The option is
ammonia plants, as can be seen in the plant overviews pre- particularly practical for transport with ship, where CO2 most
sented by Ritter and Ebner [5]. This is probably due to a high likely will be transported in liquid form.
refrigeration demand. Tokyo Gas (Japan) used low-temperature separation to
capture CO2 from the off-gas (or retentate) of a reformer
Low-temperature separation of CO2 membrane reactor (see Section 7.4). The gas had a high CO2
CO2 can be separated from gases with higher boiling temper- concentration (70e90%), and the CO2 was liquefied through
atures by cooling and physical phase separation. Coal and compression and cooling. Over 90% of the CO2 in the off-gas
natural gas derived syngases have generally CO2 partial was captured. The overall efficiency (HHV) of their process
pressures above the CO2 triple point pressure, and are there- was 81.4% for production of hydrogen without CO2 capture,
fore suitable for vapoureliquid separation [20]. and was only reduced to 78.6% when the low-temperature CO2
There are many process design options for low- capture was introduced [65].
temperature separation. One possible process sheet for low- The low-temperature separation process consists of well-
temperature capture from coal gasification syngas is pre- known process components only, and there should be no
sented by Berstad et al. [62] (Fig. 7). First drying (eg. with mo- technical constraints to hinder large-scale low-temperature
lecular sieves) is necessary in order to avoid solid formation. CO2 separation from syngas.
The syngas is then compressed with intercooling to

Fig. 7 e Exemplified process flow diagram for low-temperature syngas separation.


i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 1 ( 2 0 1 6 ) 4 9 6 9 e4 9 9 2 4979

Table 2 e Summary of performance for different options for hydrogen and CO2 separation from syngas. For the high-purity
product, literature values are given for purity and recovery. Where not specified in the source, % is assumed to be mol%. For
the low-purity product values in brackets are approximate values calculated based on syngas compositions from Table 1.
Values are given on dry basis.
Adsorption Adsorption Absorption Absorption Membrane Low -temperature
e H2 PSA e CO2 VSA e MDEA e Physical e Pd-based CO2 capture
H2 purity, mol% 98e99.9999þ Low (<91) Low (58a) Low (83e86) 99e99.995 Low (81e83)
H2 recovery, % 70e95 High High High n/a High
CO2 purity, mol% Low (39e57) >97 99.9 95e99.7 Low 99.7e99.9
CO2 recovery, % High >90 95 90e97 High 85e90
Source [5,27] [31,66] [16] [46] [50] [62,63]
Syngas in source SMR SMR Air-blown ATR Gasified coal SMR Gasified coal
a
Note that this value is for air-blown ATR for power generation. The hydrogen contains 40% nitrogen.

Technology performance summary separation in sorption-enhanced WGS, and that the


reforming/gasification step, the WGS step and CO2 separa-
A summary of separation performance for the most relevant tion can be combined in sorption-enhanced reforming. Most
technologies presented above are given in Table 2. Note that of the technologies that produce high-purity hydrogen will
the selected figures come from various sources, and the pro- produce impure CO2, while most of the technologies that
cesses are not always optimised for hydrogen production. produce CO2 of transport quality will produce impure
Purity and recovery values are dependent on the use of re- hydrogen.
sources such as adsorbent, steam, membrane area, refriger-
ation etc. Membrane reactors
In membrane reactors for hydrogen production, the chemical
reactions take place in membrane reactors where hydrogen or
CO2 is selectively removed. This shifts the equilibrium-limited
Advanced hydrogen production with CO2 capture reaction towards the product side, giving increased conver-
sion, and/or allowing to carry the reactions out at milder
Integrated syngas production and gas separation thermal conditions.
This field has been subject to substantial research. The
The hydrogen producing reactions are equilibrium-limited, amount of papers on membrane reactors for hydrogen pro-
which implies that if hydrogen or CO2 is continuously duction has escalated since 1996, and more than 100 papers
removed, the reactions will be shifted in favour of increased have been published each year since 2008, as shown by Gal-
conversion. This can be obtained in practice by combining lucci et al. [50]. Although CO2 selective reactors have been
the reaction and separation steps, which can lead to advan- studied [53,67,68], research and development of hydrogen
tages such as increased energy efficiency, reduced reactor selective reactors for hydrogen production are far more
or catalyst volume etc. The concept of such advantageous advanced, and focused on in this paper. This might be
combinations of process steps is known as process explained by looking at the reaction stoichiometrics: the
intensification. motivation for hydrogen removal is higher, because it will
There are several technologies for hydrogen production have a higher effect on conversion (for the overall reaction)
where the reaction and separation steps are integrated: compared to CO2 removal.

& Wateregas shift membrane reactors (WGS-MR)


& Steamemethane reforming membrane reactors (SMR-MR)
& Sorption-enhanced wateregas shift (SE-WGS)
& Sorption-enhanced steamemethane reforming (SE-SMR)

The technologies are shown schematically in Fig. 8. The


figure shows the conventional process route in the center,
where fuel is transformed into syngas by reforming or
gasification and further to hydrogen and CO2 (shifted syn-
gas) by the WGS reaction. The hydrogen is thereafter puri-
fied and/or CO2 is captured using different technologies. On
the left-hand side it can be seen that the WGS step can be
combined with hydrogen separation in a WGS membrane
reactor, and that the reforming/gasification step, the WGS
step and the hydrogen separation step can be combined in a
reformer membrane reactor. On the right-hand side it can Fig. 8 e Overview on integrated syngas production and gas
be seen that the WGS step can be combined with CO2 separation technologies.
4980 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 1 ( 2 0 1 6 ) 4 9 6 9 e4 9 9 2

Membrane property requirements. The membrane in a mem- Conventional Cu- and Fe-based catalysts are not well
brane reactor has to be able to operate under the thermal suited for WGS-MRs due to a retardation effect of the reaction
conditions where the reaction takes place, and this has been a products that is more intense in membrane reactors. There is
big motivator for research on high-temperature membranes. therefore focus on the development of alternative catalysts,
Under normal operation (no equilibrium shift), relatively mild such as Cu-ceria and precious metals [14].
thermal requirements (200e400 ! C) are present under the The research on WGS-MRs is presently on lab scale, but it is
WGS reaction, higher temperatures are required for the ready for transition to pilot scale [70].
reforming of natural gas (500e900 ! C), and gasification of coal
often requires temperatures exceeding 1000 ! C. It is also SMR membrane reactors. In an SMR-MR, the SMR, WGS and
important that the membrane can withstand high pressure, hydrogen purification process steps are combined (Fig. 10).
and has a high durability. Furthermore, the hydrogen Normally, the chemical reactions have to be carried out at
permeability must be high e it is critical that the hydrogen flux different operating conditions in order to obtain sufficient
is comparable to the rate of the catalytic reaction [47]. conversion and reaction rates. However, when hydrogen is
It is also critical to develop membranes that are not continuously removed, the resulting equilibrium shift makes
poisoned by the components that are inevitably present in it possible to carry out both these reactions simultaneously.
the syngas. Presently many high-temperature membranes The SMR reaction is strongly endothermic, and the WGS
are vulnerable for certain chemical compounds. For reaction mildly exothermic. In total, heat has to be added to
instance, for palladium based membranes the presence of the reaction system, and conversion is favoured at high
components such as H2S, HCl, CO2 and CO can decrease the temperatures (modern plants operated at >900 ! C). Among
performance. The presence of H2S can cause a significant the hydrogen membranes, ceramic membranes have the
loss of hydrogen flux [69]. Sulfur components can be closest operating temperatures (600e900 ! C). Some of them
removed prior to the membrane reactor in the process, but are promising for integration with SMR [71]. Also membranes
CO2 and CO will be present in the syngas. Most critical is the with slightly lower operating temperatures can be used,
CO adsorption, but it is more evident at temperatures below because the SMR can due to the equilibrium shift be carried
250 ! C [14]. out at lower temperatures [50]. Like for WGS-MRs, conver-
sion can be increased by using sweep gas and by increasing
WGS membrane reactors. In a WGS-MR, the WGS reaction is pressure [72].
combined with hydrogen membrane purification (Fig. 9). The Tokyo Gas has in cooperation with Mitsubishi Heavy In-
WGS reaction is exothermic, and conversion is therefore fav- dustries demonstrated small-scale (40 Nm3/h) membrane
oured at low temperatures. However, when hydrogen is reformer systems with hydrogen production. They first
continuously removed, the equilibrium is shifted, and it is developed a system with hydrogen production efficiency of
possible with a higher conversion at higher temperatures [14]. 70e76% (HHV) and product hydrogen purity higher than
This reduces the cooling demand. Operating temperatures of 99.999% [73]. The reformer was a packed bed membrane
300e500 ! C are suitable for the WGS-MR, and various micro- reactor with a <20 mm Pd-alloy membrane, and it was tested
porous, dense metallic and dense ceramic membranes can be for more than 3000 h. Towards the end of the testing period,
operated at these temperatures [50]. impurity concentrations in the permeate started to increase.
As for normal WGS increased S/C ratio increases conver- However, the purity of hydrogen was still higher than 99.99%
sion. However, a too large amount of steam can negatively at the end of the durability test. Later they developed an
affect the membrane structure. Increased pressure increases improved system with a hydrogen production efficiency of
the hydrogen transport over the membrane and therefore also 81%. They found that key issues for commercialization of their
the conversion. However, for microporous membranes, that reformer system is long-term durability and cost [74]. This
are not perfectly hydrogen selective, it has been observed that pilot is the largest membrane reactor that has been demon-
an increased pressure on the reactor side has given an strated for hydrogen production so far.
increased permeation of the reactants. Furthermore, mass
transport can also be increased by sweep gas on the permeate Reactor configuration. Traditional SMR and WGS reactors are
side that decreases the partial pressure of hydrogen. Sweeping packed bed reactors, and the simplest and most studied
is most effective for membranes with high hydrogen selec- membrane reactor type is the packed bed membrane reactor
tivity [14]. In the case of high-purity hydrogen production, configuration. However, with such reactors the hydrogen
sweeping with steam is most relevant, since it can be removed
by condensation.

Fig. 9 e Principle of a WGS-MR. Fig. 10 e Principle of an SMR-MR.


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transport between the catalyst bed and the membrane wall the sorbent is to be mixed with metallic catalyst in entrained
can be rate limiting. If this transport is slower than the flow reactors.
hydrogen transport through the membrane, a concentration
gradient between the catalyst bed and the membrane will Sorption-enhanced WGS. The principle of SE-WGS is shown in
emerge. This effect is known as concentration polarization Fig. 11. In the reaction step, adsorption of CO2 shifts the re-
[75,76]. Furthermore, temperature control is quite difficult in action towards increased hydrogen yield. This is followed by a
packed bed membrane reactors, and a decreased temperature decrease in pressure and/or increase in temperature, and
on the membrane surface can lead to a lower hydrogen flux purging with steam, giving desorbed CO2 and regenerated
while an increased temperature can lead to cracks in the sorbent. A semi-continuous process can be performed with
membrane surface. Finally, to limit pressure drop along the fixed bed reactor columns packed with WGS catalyst pellets
reactor, large catalyst particles have to be used, and this gives and CO2 sorbent pellets. Several columns are then run in
intra-particle mass transfer limitations [50]. parallel, but at different stages in the process cycle with multi-
There is an increasing interest in novel reactor configura- level depressurisation and repressurisation steps, similar to
tions such as fluidized bed membrane reactors and micro- the concept used for PSA. Alternatively, a continuous process
membrane reactors. Gallucci et al. [50] argues that industrial can be performed with circulating fluidized bed reactors: one
types of membrane reactors for production of pure hydrogen reactor where the sorption-enhanced reaction takes place and
most likely will be based on such reactor configurations, and one reactor for regeneration of the sorbent.
that the success of membrane reactors for hydrogen produc- Due to the equilibrium shift, the exothermic WGS reaction
tion are highly dependent on design of innovative reactor can take place at higher temperatures than normal, which
concepts. improves reaction kinetics and reduces the need for large
It should be noted that increased conversion due to equi- cooling and reheating systems. The shift also allows lower S/C
librium shift also can be obtained by operating membrane ratios, reducing the steam demand [80]. Laboratory tests have
modules in sequence with reactors, as demonstrated in a pilot shown a significant improvement in CO conversion for SE-
for SMR [54] and by simulation for WGS [77]. WGS both using hydrotalcites [82,83], and calcium oxide
[80,84], and simulation studies have shown promising per-
Sorption-enhanced hydrogen production formance for optimized SE-WGS processes [85].
The concept of sorption-enhanced hydrogen production is to Experiments have shown both that typical WGS catalysts
use adsorbents to selectively remove one or more of the are robust towards periodic atypical conditions encountered
products formed in the equilibrium-limited reactions used in within a SE-WGS cycle [86], and that a complete CO conver-
hydrogen production, shifting the equilibrium and obtaining sion can be obtained by SE-WGS without any catalyst [87].
higher conversion at milder thermal conditions. It is in prin- For process configurations based on promoted hydro-
ciple a combination of the hydrogen producing reaction steps talcite, pressure swing and purging with steam, the produced
and PSA/TSA. In sorption-enhanced WGS (SE-WGS) the WGS hydrogen is typically around 400 ! C, 30 bar and 90e95% purity,
reaction is carried out while CO2 is continuously removed by a while the CO2 is around 400 ! C and ambient pressure [87].
solid sorbent, while in sorption-enhanced SMR (SE-SMR) the Alternative processes are also suggested, for instance a pro-
SMR and WGS are carried out simultaneously while CO2 is cess where CO2 is produced at higher pressure [88]. Depending
continuously removed. There exist several review papers on on the sorbent used, H2S can be captured simultaneous with
the concept [5,78,79]. the CO2 if present. Then an additional unit for removal of H2S
from the CO2 is required. CO2 purity of 99% is realistic, and the
Sorbent properties. Common adsorbents developed for PSA optimum CO2 capture ratio is around 90e95% [89].
have low sorption capacities at the elevated temperatures The SE-WGS technology is on lab scale, but under transi-
required for SE-WGS or SE-SMR [5]. The high-temperature CO2 tion to pilot scale. ECN in the Netherlands with collaborators
adsorbents that have received most attention are calcium- established proof of principle in a lab scale facility using
based sorbents and hydrotalcite sorbents, although alterna-
tives such as mixed metal oxides are also being studied [78].
Calcium oxide is a temperature reversible adsorbent, which
has high adsorption capacity at around 500 ! C and high
regeneration rates at 700e900 ! C [5]. It is inexpensive but has a
high heat demand for regeneration [79]. The adsorption ca-
pacity can be increased while the regeneration temperature
can be decreased by addition of NaOH [80]. K-promoted
hydrotalcite is a pressure (and temperature) reversible
adsorbent with adsorption and regeneration temperatures
around 400 ! C, relatively fast kinetics, but relatively low
adsorption capacity [78,79]. This sorbent has shown to
reversibly adsorb H2S when present [81].
In general, sorbents for SE-WGS and SE-SMR require a
trade-off between high mechanical stability, high adsorption
capacity, fast reaction kinetics and low regeneration heat Fig. 11 e Principle of SE-WGS with fixed bed reactor
demand. The mechanical stability is particularly important if columns. The symbol ∑ represents the solid sorbent.
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pressure swing and potassium-promoted hydrotalcite-based aim is to integrate it with an SE-SMR process. Exhaust gas
materials under realistic conditions [90]. As a continuation of from the fuel cell afterburner will provide the heat required in
their work SE-WGS will be demonstrated on pilot scale adja- the regeneration step of the SE-SMR. They are aiming to
cent to the SSAB steel plant in Sweden in the Horizon 2020 demonstrate 70% overall efficiency for cogeneration of
project STEPWISE, which started on May 1st 2015. hydrogen and power [95].

Sorption-enhanced SMR. In SE-SMR, the SMR and WGS re-


actions take place simultaneously with CO2 separation over a Chemical looping hydrogen production
reforming catalyst mixed with a CO2 sorbent. The equilibrium
shift allows both the reforming and water gas shift reactions Different concepts for hydrogen production using chemical
to approach completion [78,91]. The principle is similar to SE- looping have developed from the concept of chemical looping
WGS, but the reactions take place at higher temperatures. combustion (CLC). In CLC an oxygen carrier (typically a metal
Circulating fluidized bed reactors are ideal for SE-SMR. oxide) is used to provide the oxygen required for fuel oxidation
Fixed-bed reactors systems have also been suggested, but in a fuel reactor. Since pure oxygen is provided, the produced
might not be optimal due to the high reaction temperature. flue gas contains mainly CO2 and H2O. The reduced oxygen
For instance, the operation of large valves at high tempera- carrier is then oxidized back to its initial state by air in an air
tures might be problematic [78]. The principle of SE-SMR in reactor and reused. Reviews on this technology are given by
circulating fluidized bed reactors is shown in Fig. 12. Heat for Hossain et al. [96] and Adanez et al. [97].
regeneration of the sorbent can be supplied either by burning The concepts developed for hydrogen production can be
fuel in the regenerator or by indirect heating from an external divided into two main classes. In the first class the oxygen
source [92]. carrier is merely used to provide pure oxygen. The air required
The equilibrium shift enables higher conversion at lower in ATR can be provided by the oxygen carrier, or the heat
temperatures than for normal SMR e typically around 600 ! C. required in SMR can be provided by integration with CLC. The
High system pressure reduces the vessel sizes, however hydrogen production process is not significantly changed in
increasing pressure of the regeneration step will require these concepts. They are described by eg. Adanez et al. [97],
higher regeneration temperature [93]. but not discussed further here. In the second class the oxygen
The SE-SMR technology is also under transition to pilot carrier is used to reduce steam in a dedicated steam reactor.
scale. It has been tested at laboratory scale by various groups These concepts are described in a review by Fan et al. [98], and
[92,94]. For instance, a hydrogen concentration of 98e99 vol% are also the focus in this section.
was obtained in an experimental bubbling fluidized bed In general the success of chemical looping processes re-
reactor after four reforming/regeneration cycles [92]. IFE quires development of oxygen carriers that are chemically
(Norway) is currently in the test phase of a 30 kW SE-SMR and physically stable throughout many cycles with reduction
prototype with a dual bubbling fluidized bed reactor system. and oxidation, and high velocity circulating transport
The reformer is run at 600 ! C and the regenerator at 850 ! C operation.
with calcined dolomite as CO2-sorbent and a commercial Ni-
based reforming catalyst [93]. Initial batch test runs with Syngas chemical looping process
biogas have given a product with ~94 vol% hydrogen and In the syngas chemical looping process a system with three
<0.1 vol% CO2 [93]. ZEG Power (Norway) has developed a reactors is proposed. The concept is illustrated in Fig. 13 with
concept for thermal integration of SE-SMR producing iron oxide as oxygen carrier. In a fuel reactor the oxygen
hydrogen and a solid oxide fuel cell producing electric power. carrier is reduced by syngas, producing a flue gas with mainly
They are currently testing a 20 kW fuel cell system, and the CO2 and H2O. The reduced oxygen carrier is sent to a steam
reactor where steam is reduced producing hydrogen, and the
oxygen carrier is partly oxidised. The oxygen carrier is then
sent to an air reactor where it is fully oxidised with air, before
it is recycled to the fuel reactor [98]. This concept can in theory
produce both high-purity hydrogen and CO2 at transport
quality. Possible impurities present in the CO2 will depend on
the syngas composition (which depends on the raw material
and potential syngas purification).
The following reactions (unbalanced) are carried out in the
three reactors:

Fuel reactor : Fe2 O3 þ CO þ H2 /Fe=FeO þ CO2 þ H2 O (9)

Steam reactor : Fe=FeO þ H2 O/Fe3 O4 þ H2 (10)

Air reactor : Fe3 O4 þ O2 /Fe2 O3 (11)

The fuel reactor is typically operated at 750e900 ! C, while


Fig. 12 e Principle of SE-SMR in a circulating fluidized bed the steam reactor is operated at 500e750 ! C. In the air reactor
reactor. The symbol ∑ represents the solid sorbent. heat is generated and a portion of this heat is transported to
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[102]. Heavy fraction of bio-oil have been tested at laboratory


scale [103].

Technology performance summary

A summary of separation performance for the technologies


presented above are given in Table 3. Only product purities are
given. Recovery cannot be defined similarly for all technolo-
gies, and limited information is available in the literature.
Hydrogen membrane reactors are hydrogen removal
focused, while sorption-enhanced reactors are CO2 removal
focused. It can be observed in Table 3 that for the hydrogen
membrane reactors, the purity of the produced hydrogen is
high while the purity of the CO2 is low. For the sorption-
Fig. 13 e Principle of the syngas chemical looping process.
enhanced reactors, the opposite can be observed. This in-
dicates that additional CO2 separation technologies are
the fuel reactor through the oxygen carrier particles, while needed downstream hydrogen membrane reactors, while
the rest will be contained in the exhaust air which can be hydrogen separation technologies are needed downstream
utilised for power production or for heating purposes. A sub- sorption-enhanced reactors. Syngas chemical looping has the
stoichiometric amount of steam can be introduced in the potential to produce both CO2 at transport quality and high-
steam reactor if more heat or power and less hydrogen is purity hydrogen. However, the types and amounts of impu-
desired [98]. rities present in the CO2 depends on the purity of the syngas
This process has been tested in a 25 kWth sub-pilot unit that is used as fuel.
operated at isothermal conditions maintained with heating Not much work has been published on benchmarking such
from heating elements. Steady profiles of 99.99% hydrogen processes for hydrogen production. This is in contrast to the
production and nearly 100% syngas conversion were ach- topic pre-combustion CO2 capture where several
ieved. The setup was also tested using methane as fuel. An benchmarking/techno-economic evaluations are performed.
average CH4 conversion and CO2 purity of 99.67% was then
achieved in the fuel reactor [99].
CO2 and hydrogen product purity requirements
Direct chemical looping gasification
In direct chemical looping gasification the same setup is used When selecting a process route for production of hydrogen
(Fig. 13), but coal or other solid fuel is gasified directly in the with CO2 capture, attention must be given to the requirements
fuel reactor. on both CO2 and hydrogen purities. Complexity lies in that
Utilisation of solid fuels in chemical looping is chal- these requirements are not always fully known. Concerning
lenging due to operational aspects such as increased oxygen the requirements for CO2 purity, most research has been done
carrier deactivation, slow gasification requiring long resi- on the requirements for CO2 pipeline transport, while it is
dence time in the fuel reactor, and requirement of good scarce for ship transport. At the time of writing this paper, ISO
contact between oxygen carriers and released volatiles standards for CO2 pipeline transport, are being elaborated
[100]. In a proposed design the fuel reactor is divided into (ISO/TC 265). Hydrogen purity requirements will vary
one region for solid fuel injection and devolatilization, one depending on the application. For some applications there are
region for reduction of oxygen carrier by gaseous volatiles, ISO standards available [104e106].
and one region for fuel gasification and oxygen carrier
reduction [101]. CO2 purity requirements
Tests of several coal direct chemical looping combustion
units with sizes of 0.5e100 kWth and different types of coal The CO2 purity specifications are dependent on transportation
and oxygen carriers have been reported. Gas conversions of method (pipeline or ship transport) as well as the final desti-
77e100% were achieved, with lower conversions of the solids nation (eg. storage in saline aquifers, EOR, or use in industrial
[100]. In one of these units also biomass was tested as fuel products).

Table 3 e Separation performance of technologies for integrated hydrogen production and gas separation. Values are given
on dry basis.
WGS-MR SMR-MR SE-WGS SE-SMR Syngas chemical looping
(Pd-based) (Pd-based) (hydrotalcite) (dolomite) process
H2 purity, % 99.99a 99.99 90e95 94e98 99.99
CO2 purity, % Low Low ~99 n/a '99.67
Source [73,74] [87] [78,93] [99]
a
Assumed similar to SMR-MR.
4984 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 1 ( 2 0 1 6 ) 4 9 6 9 e4 9 9 2

When transported in pipelines, the CO2 is usually at su- Hydrogen purity requirements
percritical pressure and subcritical temperature. Recom-
mendations on CO2 purity for transport in pipeline and The purity requirements of hydrogen vary largely depending
storage in saline reservoirs or use for EOR have been given by on the application of the hydrogen. The largest present and
several groups such as the Dynamis project [107] and The potential future uses of hydrogen are (cf. Fig. 2):
European Benchmarking Task Force [108]. NETL provided in
2012 an overview of estimated permissible CO2 impurity & Refining/hydrocarbon upgrading
levels from studies, pipeline design guides, pipe trans- & Ammonia production
portation specifications and sequestration plant experience, & Methanol production
and based on this they set recommended CO2 purity speci- & Fuel cells (transport, power generation)
fications for pipeline transport, EOR and saline reservoir & Combustion (eg. atmospheric boilers, gas turbines, internal
sequestration [109]. They recommended CO2 concentration of combustion engines)
>95 vol% for all cases, with <300 ppmwt H2O, <35 ppmv CO
and <0.01 vol% H2S. The concentration should be <4 vol% for Out of these users methanol production is not relevant in a
all non-condensable gases for pipeline transport and saline CO2 capture context, since CO and CO2 is used in the methanol
reservoir sequestration, and for EOR the concentration synthesis, and no excess CO2 is produced [111]. Current
should be <0.01 vol% for O2 (potential unwanted exothermic hydrogen purity requirements for the other major users are
reactions with hydrocarbons) and <1 vol% for other non- discussed below and summarised in Table 4.
condensable gases (potential reduced miscibility). The limits Hydrogen is needed in refineries mainly in hydrotreating
are set based on considerations such as toxicity, compression and hydrocracking units. Hydrogen can either be imported or
work, and risk for hydrate formation, running ductile frac- produced by SMR or POX at the plant. In these cases, hydrogen
tures and corrosion. purities around 95% are usually aimed at. The content of
In the case of CO2 captured from hydrogen production, the sulfur components should be limited, in order to prevent
effect of loosing hydrogen with the CO2 should be considered. degradation of catalysts [60,112].
Since hydrogen is a valuable product, the amount of hydrogen In production of ammonia, hydrogen is reacted with ni-
in the CO2 should be limited, where the optimal limit depends trogen, which usually is introduced as air in the reforming
on economic considerations. This will most likely motivate process. The H2/N2 mixture must have very low levels of CO,
CO2 purities higher than 95 vol%. CO2, water and sulfur components, as these components
For ship transport of CO2 less work has been done on CO2 poison the ammonia synthesis catalyst [38].
purity recommendations. CO2 can be transported with ship in Hydrogen for use in fuel cells need to have very low levels
compressed or liquefied form. Ship transport of compressed of CO and sulfur components in order to avoid catalyst
CO2 will require expensive pressure vessels, so it is here poisoning, and very low level of NH3 to protect the membrane
assumed that the CO2 will be transported in liquid form. A from degradation. The amount of CO2 and hydrocarbons must
tentative value for water content is then 50 ppm H2O, to avoid also be kept relatively low in order to limit performance
operational problems in the liquefaction process. The exact degradation. ISO standards have been developed for PEM fuel
specification will depend on the liquefaction process and cells for automotive and stationary purposes [105,106].
equipment [110]. Volatile gases will be separated from the Besancon et al. [23] have studied the impact of impurities in
captured CO2 as part of the liquefaction process, whereas hydrogen produced by SMR, ATR and coal gasification on fuel
heavier compounds have to be removed prior to liquefaction. cell performance, and have suggested to relax the restrictions
The optimum extent of CO2 purification performed prior to the for some components.
liquefaction process compared to the extent of purification For combustion of hydrogen in gas turbines, inert compo-
performed as a part of the liquefaction is not settled yet. nents in the fuel is not an issue. With today's technology, the

Table 4 e Hydrogen purity requirements for various hydrogen users in the energy and transport sectors.
H2 purity (min) [%] Impurity limits (max) [ppm] Source
Refining ~95 S: low levels [60,112]
Ammonia 23e25 (N2:74e77) CO2, CO, H2O and S: low levels [5,38]
PEM fuel cells for automotive 99.97 H2O:5, HC:2, O2:5, He:300, N2 þ Ar:100, CO2:2, CO:0.2, S:0.004, NH3:0.1 [105]
purposes H2O:5, HC:100, O2:5, He þ N2 þ Ar:500, CO2:2, CO:0.5, S:0.01, NH3:0.1 [23]
PEM fuel cells for stationary Cat. 1 50 H2O:NC, HC:10, O2:200, N2 þ Ar þ He:50%, CO:10, S:0.004 [106]
purposesa Cat. 2 50 H2O:NC, HC:2, O2:200, N2 þ Ar þ He:50%, CO:10, S:0.004 [106]
Cat. 3 99.9 H2O:NC, HC:2, O2:50, N2 þ Ar þ He:0.1%, CO:2, S:0.004 [106]
Gas turbines Low Limited amount of Na, K, V and S [115]
Industrial fuel (eg. power 99.90b H2O:NC, HC:NC, O2:100, N2:400, S:10 [104]
generation or heat
energy source)

NC ¼ not to be condensed, HC ¼ Hydrocarbons on methane basis, S ¼ Sulfur compounds.


a
The categories are defined to meet the needs of different stationary applications.
b
This value is from an ISO standard and should not be taken as a definite limit.
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hydrogen will in any case be diluted with large amounts of Hydrogen production for refineries with CO2 capture by
nitrogen or steam to reduce the combustion temperature, and absorption
thus limit NOx emissions [113]. Combustible components such
as CH4 and CO can be present in the hydrogen, but it has to be In the Quest project (Alberta, Canada), a hydrogen production
taken into consideration that they influence the combustion plant for heavy oil upgrading is being retrofitted. CO2 will be
characteristics of the fuel [114]. The content of components captured after SMR using activated MDEA. Around 1 Mtonne/
that can cause high-temperature corrosion such as Na, K, V year of CO2 will be captured and stored in a saline formation.
and S has to be limited. However, the limit depends on The purity of the CO2 prior to transport is expected to be 99.2%
whether coatings are applied to the gas turbine blades, or [120].
whether corrosion inhibitors are added to the fuel [115]. In the ACTL Sturgeon project (Alberta, Canada), a new re-
An ISO standard for industrial fuel (eg. power generation or finery complex is under construction where CO2 capture will
heat energy source) has been developed [104], with a purity be integrated. Generated asphaltene residue will be gasified,
limit of 99.9% hydrogen and eg. maximum 400 ppm nitrogen. followed by WGS and a Rectisol® unit that will remove 95% of
This seems strict in light of the low purity requirement due to the CO2 at a purity of 99.6% and produce a separate stream
technical limitations discussed for gas turbines. with sulfur components. The CO2 recovered by the Rectisol®
It may in some cases prove to be costly to produce unit is expected not to need drying. The resulting hydrogen
hydrogen with as high quality as specified in the ISO stan- contain <0.1 ppmv sulfur components. The CO2 will be used
dards. Use of hydrogen for fuel cells and combustion are for EOR [120,121].
emerging technologies and it can therefore be expected that
as more experience is gained about the production and use of Hydrogen production for refineries with CO2 capture by VSA
hydrogen for these purposes, both ISO standards will be
revised. Air Products and Chemicals is running a large-scale demon-
The hydrogen purity requirements discussed above are stration plant at the Valero refinery in Port Arthur (Texas,
relevant in cases with on-site hydrogen production and use. USA). They have retrofitted a hydrogen production facility by
For other cases it may be that transport and/or intermediate adding a vacuum swing adsorption (VSA) unit, that captures
storage will put the highest restrictions on hydrogen purity. If wet CO2 between the already existing SMR and PSA units. The
hydrogen is to be transported over long distances, liquefaction wet CO2 is compressed and dried, and transported with
and transportation by ship is the preferable option. Also, for pipeline for onshore EOR. The produced hydrogen is trans-
road transport to hydrogen fuelling stations, liquid hydrogen ported by pipeline for use in refineries. It captures 1 Mtonne/
by truck may be preferable compared to compressed gas, if year of CO2, and has been in operation since 2013. More than
feasible from a safety point of view [116]. Hydrogen is liquefied 90% of the CO2 with purity greater than 97% is captured from
at $253 ! C, and although current PSA technology can deliver syngas that consists of more than 15% CO2 [28e30,66].
hydrogen with 10 ppm impurities or less, additional purifica-
tion to <1 ppm through adsorption is required, and is effec-
tuated inside the cold box at $193 ! C [117]. Altogether, Selection of process route
hydrogen that is transported in the liquid state will require a
purity that is significantly higher than the requirements listed As reviewed in this paper, there are many possible process
in Table 4. routes for hydrogen production with CO2 capture.

Retrofit versus new plants


Large-scale plants
The existing large-scale plants for hydrogen production with
There exist several large-scale plants that combine the CO2 capture have been developed by retrofitting existing
hydrogen production and purification and CO2 capture tech- plants. The ease of retrofit depends on the hydrogen purifi-
nologies various ways. cation facilities present at the plant. Some plants (in particular
ammonia/fertiliser plants) remove CO2 with absorption units,
Ammonia synthesis with CO2 capture by absorption which produce CO2 at high concentration (that they partly
need in their process). Two such fertiliser plants have been
At fertiliser plants, ammonia is produced with hydrogen as an retrofitted simply by compressing and dehydrating CO2 from
intermediate product. As mentioned in Section 5.2, hydrogen the existing absorption units. Hydrogen purification using PSA
used in ammonia synthesis need to have low levels of CO2, CO, gives hydrogen at higher purity, but results in a waste stream
H2O and sulfur. CO2 and sulfur removal is often done by ab- with lower CO2 concentration and a significant amount of
sorption (eg. Benfield and Selexol processes). Some of the CO2 valuable hydrogen. The Port Arthur plant that produce
can be used at the plant while the rest is usually emitted. Such hydrogen for refineries purified the hydrogen using PSA, and
plants are relatively easy to retrofit with CO2 capture, by has been retrofitted by addition of VSA units (with compres-
installing compression and TEG dehydration systems. So far sion and dehydration of captured CO2) upstream the existing
two fertiliser plants have been retrofitted this way: the Enid PSA units.
(USA) and Coffeyville (USA) plants ([37,118e120]). The Agrium When designing new plants, we are free to select the route
plant (Canada) is being retrofitted with anticipated start of between the feedstock and the products. The feedstock can
operation in 2015 [42]. vary between biomass, coal, oil or natural gas. The required
4986 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 1 ( 2 0 1 6 ) 4 9 6 9 e4 9 9 2

CO2 quality depends on whether it will be transported by combined cycle, generating the power needed by the system,
pipeline (>95% CO2) or by ship (liquefied CO2). The required plus a surplus of electricity that potentially could be employed
purity of the hydrogen is low if it is to be used as fuel, while the for hydrogen liquefaction [130].
purity must be very high for certain other applications e in For the case of sorption-enhanced WGS or SMR using
particular for automotive PEM fuel cells. When the constraints calcium-based sorbents, high-temperature heat is needed for
are set for (i) feedstock, (ii) CO2 transport option, and (iii) the regeneration step taking place at 700e900 ! C. This case is
hydrogen application, the most suitable syngas production particularly benefited by integration with a high-temperature
and separation technologies should be chosen. heat source. For instance, the heat can be provided by utilising
waste heat from a SOFC as suggested by ZEG Power [95].
Process intensification Furthermore, both hydrogen and CO2 are generated at high
temperatures, and heat could be recovered from these
As reviewed in Section 4 there are several possible options for streams.
process intensification. As summarised by Mayorga et al.
[122], sorption-enhanced hydrogen production can simplify
hydrogen purification, allow less expensive materials in re- Combination of technologies
actors due to decreased temperatures, reduce or possibly
eliminate carbon deposition in the reforming reactor, elimi- Most of the reviewed technologies can not produce high-
nate shift reactors (for SE-SMR) and decrease the size of heat purity hydrogen and CO2 at transport quality simultaneously
exchanger equipment. Also, the WGS catalyst may be elimi- (cf. Tables 2 and 3).
nated [87], and there is no need for a separate CO2 capture Hydrogen can be produced at very high purity using PSA or
step. Membrane reactors can give reduced capital costs due to hydrogen membrane technologies, and such technologies are
reduced reactor size, reduced downstream separation costs preferred for production of hydrogen eg. for PEM fuel cells or
and operation in milder thermal conditions (resulting in less for transport in liquid form. However, the waste stream will be
heating/cooling) [14,50]. Also the concept of coal/biomass a mix of CO2, hydrogen and other impurities, and an addi-
direct chemical looping gasification processes implies process tional separation unit dedicated for CO2 capture has to be
intensification: the solid fuel is gasified directly in the fuel added to the process. This is the case in the configuration
reactor, eliminating a preliminary process that supplies syn- shown in Fig. 3 showing the presently most mature route: a
gas to the fuel reactor. This drastically simplifies the fuel CO2 absorption unit is added upstream a PSA unit. Although
conversion scheme [98]. CO2 absorption is considered most mature for CO2 capture in
Drawbacks with these technologies are low maturity e general, it is not necessarily the best option in the context of
they are currently on maximum pilot scale. Even though the hydrogen production. At the Port Arthur refinery, a VSA unit
number of process units are decreased, the process they are was installed for CO2 capture upstream the existing PSA units.
replaced with entail several technical challenges due to Furthermore, as shown by Berstad et al. [63] low-temperature
increased complexity. CO2 separation is competitive to absorption from gases with
high CO2 partial pressures (in this context syngas from coal
Process integration gasification or off-gas from a hydrogen purification unit). For
instance, Tokyo Gas [65] chose to purify the SMR-MR off-gas by
The requirement for heating and cooling in the processes, and liquefaction, and this reduced the overall efficiency of the
the production of waste streams containing combustible process with less than 3%-points compared to the same pro-
components, indicates that there are potentially great benefits cess with no CO2 capture. The option of low-temperature
from integration with other processes. separation is particularly interesting in cases where the CO2
Several configurations for co-production of hydrogen and will be transported by ship, since it provides CO2 in liquid
electricity with CO2 capture have been investigated in simu- form.
lation studies. Examples are studies on systems with coal In the case of absorption, low-temperature CO2 capture,
gasification or natural gas reforming, solvent absorption and and sorption enhanced WGS and SMR, transport grade CO2 (in
PSA that are closely integrated with combined cycles or con- gas or liquid form) can be achieved, but the hydrogen-
ventional steam cycles [123,124], studies on ATR with WGS- containing off-gas normally needs further purification. For
MRs integrated with combined cycle [125], and studies on an instance, Barelli et al. [79] mention that although SE-SMR can
IGCC-based concept where the produced hydrogen-rich syn- directly produce higher purity hydrogen than a conventional
gas is either purified in a PSA and exported, or used in a reactor, it is not enough to satisfy high-purity customers, and
combined cycle for power generation, with close integration an additional unit is required to purify the effluent gas.
between the subsystems [126]. Chemical looping hydrogen One exception is PSA technology, that potentially can
production appears to be ideal for co-production of hydrogen produce both high-purity hydrogen and CO2 [33]. The same
and electricity given successful scale-up of the technology, concept can also be applied to sorption enhanced processes
and such processes with coal and biomass direct chemical that are based on fixed beds and pressure-swing. However, the
looping have been simulated and optimised [127e129]. Also, a production of an off-gas containing both these components
self-sustained system where a coal gasification hydrogen and impurities can hardly be avoided. Another exception is
production plant combining membranes and low- chemical looping hydrogen production that potentially can
temperature separation has been studied. The off-gas from produce streams with high-purity hydrogen and CO2 at
the low-temperature separation system was used as fuel in a transport quality.
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 1 ( 2 0 1 6 ) 4 9 6 9 e4 9 9 2 4987

Proper considerations have to be taken when technologies produces 16.5 kg CO2 per kg hydrogen. Furthermore, we as-
are combined, making sure that each technology as far as sume that net CO2 emissions from renewables and biomass
possible operate in its optimal operating windows. are negligible, that CCS technologies have 90% CO2 capture
rate, and that the global hydrogen production scenario will be
Trade-off similar to the US scenario. An annual production of ~10 EJ
hydrogen (~83 Mtonne) then corresponds to ~0.1 Gtonne CO2
In general we can say that the purer product, the more emitted to the atmosphere.
resource use and valuable products lost in the off-gas, and as Road transport accounted for 5.5 Gtonne CO2 emissions in
discussed in the previous section, high-purity products 2013 [131]. Around 2/3 of the emissions from road transport
require more complex process routes. Hence, there is a trade- come from LDVs while around 1/3 come from HDVs [1]. 10 EJ/
off situation between the advantages with high-purity prod- year of hydrogen could be used to fuel FCEVs that replace 25%
ucts, and the resources used to purify them, and it is worth- of the LDV fleet and 10% of freight road transport fleet [3].
while to further investigate the optimum limits for CO2 and Referring back to the previous paragraph, this means that
hydrogen purity. vehicles that now account for ~1.1 Gtonne of CO2 emissions/
Furthermore, the CO2 capture rate will be subject to trade- year could be replaced by vehicles that altogether account for
off with the resource use. As long as the cost of CO2 emissions ~0.1 Gtonne CO2 emissions/year.
is low, there will be additional costs associated with CO2 The picture presented here is simplified, and merely
capture. The specific cost per amount of CO2 avoided is a intended to provide an order of magnitudes. Growth in the
parameter that should be kept optimum when selecting pro- global car fleet is not taken into account, and fuel and power
cess route. consumption along the CCS and hydrogen transport chains
will increase the CO2 emissions (refer to Section 8.3 below for
CO2 emissions from hydrogen liquefaction). However, it is
Outlook on production and use of hydrogen in a evident that introduction of hydrogen as fuel in the transport
CCS context sector, with the hydrogen produced mainly by a mix of re-
newables and fossil fuels with CCS has the potential to dras-
The global CO2 emissions from fuel combustion were tically reduce CO2 emissions in the transport sector.
32.2 Gtonne in 2013. The different shares of main CO2 emitters
were: electricity and heat production (42%), transport (23%) Use of hydrogen in industry and power generation
and industry (24%) [131]. Increased use of hydrogen as energy
carrier can help reducing these emissions, provided that the For the anticipated second largest user of hydrogen in the
hydrogen production, compression/liquefaction and trans- future, industry, the picture is more heterogeneous since the
port in itself do not contribute to considerable CO2 emissions. usefulness of hydrogen will vary from one industrial appli-
Globally, the use of hydrogen is around 7.2 EJ/year, with a cation to another. Industry must reduce its direct CO2 emis-
distribution among end-users as shown in Fig. 2. This corre- sions by 17% by 2025 to meet 2DS targets [132]. IEA [2] mention
sponds to CO2 emissions of around 0.5 Gtonne/year [3]. The that hydrogen can be used to substitute coal and coke in ore
amount of future hydrogen production will depend on tech- reduction (although the technology currently is far from the
nology development, economic factors such as cost of demonstration phase [133]), and that hydrogen could be used
renewable energy versus the cost of fossil fuels, and on po- to replace fossil fuel-based feedstocks and energy use in
litical decisions. In the IEA high hydrogen 2DS (also shown in various ways in the chemical sector.
Fig. 2), a significant increase in the global use of hydrogen is From the perspective of power generation, extensive
anticipated by 2050. In this scenario the two main causes of research has been undertaken for more than 20 years in order
increased hydrogen use are transport (~10 EJ/year) and in- to understand and realize safe and stable low-emission
dustrial use (~15 EJ/year). hydrogen combustion, and this research will need to
In the rest of this section we briefly discuss the possible continue. The main problem with hydrogen combustion is the
impact of hydrogen production with CCS for the transport formation of NOx due to high combustion temperatures. Dilu-
sector, the potential for use of hydrogen with CCS in industry tion with steam or nitrogen gives an efficiency penalty, since
and power production, and the potential CO2 emissions from the nitrogen and the steam have to be produced. An alternative
liquefaction of hydrogen. approach subject to research is a system with premixing of
hydrogen with air. For this possible solution the high flam-
Emission reductions in the transport sector mability and low ignition temperature of hydrogen causes
safety and stability issues, such as the possibility for flashback
In the hydrogen production pathway in the high-hydrogen [113,134]. However, much effort has been put into modelling of
2DS for the US, the shares of hydrogen production for trans- hydrogen combustion, which has increased the understanding
port in 2050 are: 4% reforming of natural gas without CCS, 36% of eg. hydrogen flammability [135]. If these challenges were
reforming of natural gas with CCS, 29% gasification of coal resolved, both power generation with pre-combustion capture
with CCS and the rest is biomass gasification and low cost of CO2 and hydrogen-fuelled combined cycles for power gen-
renewable electricity [3]. To make a simple estimate on CO2 eration would be attractive options for efficient low-carbon
emissions from transport in 2050, we calculate from the power generation with good load-following capacity. Such
chemical reactions involved that natural gas reforming pro- power plants are expected to be able to balance the natural
duces 7.7 kg CO2 per kg hydrogen, while coal gasification variations in power generation from renewable energy
4988 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 1 ( 2 0 1 6 ) 4 9 6 9 e4 9 9 2

sources, by producing hydrogen by electrolysis in periods with Again several aspects are subject to trade-off: the benefits of
excess power production, and utilising it in periods when the onsite hydrogen production versus the benefits of dedicated
power production is low. Another alternative is to mix in a plants, transport of hydrogen versus transport of CO2, and use
fraction of hydrogen in the fuel of gas turbines run on natural of limited renewable power on electrolysis versus hydrogen
gas. This is a way of utilising for instance low-grade hydrogen liquefaction/compression.
or PSA off-gas. Furthermore, stationary fuel cells could play a
role in future hydrogen-fuelled power generation, eg. for do-
mestic purposes [136] or in combination with gas turbine Conclusions
combined cycles [133].
When evaluating fuel substitution in the industry, as well Methods for production and purification of hydrogen from
as stationary power generation with hydrogen, it should be fossil fuels with CO2 capture are reviewed. Hydrogen pro-
highly relevant to investigate in detail both the total carbon duction with CO2 capture implies the production of two
footprint and the total efficiency from hydrogen production, product streams: hydrogen at the desired purity and CO2 at
via compression/liquefaction, transport and storage to the transport and storage quality. An additional waste stream
end user. As an example, IEA mention for the case of com- with some combustable components will also be produced in
bined cycle utilizing hydrogen from electrolysis that the effi- most cases. Producing hydrogen from fossil fuels, while
ciency for the power generation is high (60%), but the total capturing the CO2 for transport and storage is a matter of
efficiency is below 32% due to the electrolyser and hydrogen matching hydrogen and CO2 separation technologies in a best
storage [133]. possible manner, taking into account the planned transport
option for the CO2 and the planned use of the hydrogen.
CO2 emissions between hydrogen production and end user Hydrogen production with CO2 capture could be a key tran-
sition technology for moving in the direction of a sustainable
Production of hydrogen with CO2 capture may take place hydrogen-using society, with the potential for large emission
onsite industrial plants or fuelling stations, or it may take reductions in the transport and industry sectors.
place on large dedicated hydrogen production plants and be
transported to the users. The challenges associated with
storing and transporting hydrogen have generally lead to Acknowledgements
onsite production for large industrial users, such as for
ammonia plants [37]. Also, there are studies concerning onsite This work was conducted with support from the BIGCCS
hydrogen production with CO2 capture on fuelling stations Centre, performed under the Norwegian research program
(eg. the ZEG-project [95] and the membrane reformer project Centers for Environment-friendly Energy Research (FME). The
by Tokyo Gas [65,73]). However, hydrogen would most likely authors acknowledge the following partners for their contri-
have to be transported to small end users, and for some in- butions: Gassco, Shell, Statoil, TOTAL, Engie and the Research
dustrial sites it would not be possible with hydrogen produc- Council of Norway (193816/S60). Thanks are due to David
tion with CO2 capture for practical reasons (eg. no CO2 storage Berstad, SINTEF Energy Research for sharing his knowledge
site or transport system available). If onsite production is about hydrogen liquefaction.
found infeasible, the power demand and associated CO2
emissions for hydrogen compression or liquefaction prior to
transport, as well as the transport itself must be taken into Appendix A. Supplementary data
account when considering the CO2 emission reduction po-
tential from hydrogen energy. Supplementary data related to this article can be found at
It is beyond the scope of the present paper to provide http://dx.doi.org/10.1016/j.ijhydene.2016.01.009.
complete chain analyses of hydrogen production compres-
sion/liquefaction and transport. However, estimates are pro-
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