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H2A Delivery H2A Hydrogen Delivery Components Model Matt Ringer National Renewable Energy Laboratory February 8, 2005 Other Team Members: Mark Paster: DOE Marianne Mintz, Jerry Gillette, Jay Burke: ANL Daryl Brown: PNNL Joan Ogden: UC Davis

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H2A Delivery

H2A Hydrogen Delivery Components Model

Matt RingerNational Renewable Energy Laboratory

February 8, 2005

Other Team Members:Mark Paster: DOEMarianne Mintz, Jerry Gillette, Jay Burke: ANLDaryl Brown: PNNLJoan Ogden: UC Davis

H2A Delivery

Outline

• Hydrogen delivery definition• H2A Delivery Component Model

– Methodology– Components included– Key Assumptions

• Spreadsheet demonstration

H2A Delivery

Hydrogen Delivery• Hydrogen delivery and storage defined as the

complete set of equipment and processes used to move hydrogen from the central production plant to the forecourt station or primary usage

H2A DeliveryHydrogen Delivery Component

Model• Excel-based tool• Allow the user to determine a “generic”

hydrogen cost for a particular component• Each storage and delivery component has

separate tab• Final hydrogen cost determined using fixed

charge rate calculation– Final hydrogen cost determined in real dollars– Model assumes MACRS depreciation– Replacement capital includes for some

components

H2A DeliveryComponent Economic Analysis

• The economic results presented assume specific scenario– Scenario refers to specific situation of hydrogen

storage and delivery … therefore, the results do not apply to every hydrogen storage and delivery application

– Scenario’s used to prepare results are static and do not include dynamic cost effects likely to be applicable in real-life development of hydrogen storage and delivery infrastructure in a demand market

H2A DeliveryConsistent Assumptions

Throughout Model• Discount Rate – 10%• Dollar Year – 2005• Startup Year – 2005• Depreciation Type – MACRS• Analysis Period – 20 years• Federal Taxes – 35%• State Taxes – 6%• Total Tax Rate – 38.6%

H2A DeliveryComponents Modeled

• Hydrogen moved in either liquid or gaseous forms

Storage ComponentsDelivery Components-Compressed Gas Tube System-Bulk Liquid Hydrogen System-Geologic-Forecourt

-Truck – Tube Trailer-Truck - LH2-Pipeline-Liquefier-Compressor (one-stage and multi-stage)-Forecourt Compressor-Terminals (gaseous and liquid)

H2A Delivery

Spreadsheet Features• Yes/no toggle switches to allow for user input

or H2A standard input– Inputs turn on/off based on yes/no toggle switch

• Error messages included to alert user when input errors are made

• Multiple options for MACRS depreciation period– Includes standard MACRS table

• Color-coded to facilitate user input

Information

Optional Input

User Input Required

Calculated Cells

H2A DeliveryComponent Model Hierarchy

Component Design Inputs Component

Design/Scenario Calculations

Financial Analysis

Direct/Indirect Capital Costs

Component Capital Costs

Component Scenario Inputs

Replacement Capital

Financial / Economic Inputs

Operating and Maintenance Costs

Component Cost in $/kg of Hydrogen

H2A Delivery

Component Spreadsheet Inputs• Design Inputs

– Inputs required to design particular component

– Includes design hydrogen throughput, operating pressures, temperatures, component efficiency, system losses

• Scenario Inputs– Inputs required to design “generic” scenario for

specific component

– Includes delivery times, component availability, days of storage required, truck speed, delivery distance

H2A DeliveryComponent Spreadsheet Inputs

(cont.)• Calculations

– No inputs required; calculations required for financial analysis

• Economic Assumptions– Lifetime, discount rate, analysis period, taxes,

depreciation period, system start-up year• Capital Costs

– All component capital costs– Options to use H2A data, or user-entered data

H2A DeliveryComponent Spreadsheet Inputs

(Cont.)• Other Capital

– Land costs (assumed depreciable)– Site preparation, engineering, contingency– Options to use H2A, Peters and Timmerhaus or

other data• O&M Costs

– Labor, feedstock costs (from H2A cost projections, or user-entered)

– Property taxes, insurance• Financial Analysis

– Calculations to get component hydrogen cost ($/kg)

H2A Delivery

Financial Analysis

• Based on fixed charge rate calculation– First, capital recovery factor is calculated

D = discount rate, N=analysis period

– Present value of depreciation charges for particular MACRS recovery period calculated

∑= −+

+=

+=

N

zz

r

zrr

zr d

ddd

CRF1 1)1(

)1()1(

1

H2A Delivery

Financial Analysis (cont.)• Fixed Charge Rate Calculation

– Based on before-tax-required formula

)1(

))1(

1(1

T

tdVbTCRF

FCRc

M

nn

n

n

−+

−=

∑=

b=fraction dep. base, T=total tax rate, Vn=fraction of dep. base in year n, tc=tax credits

)1()*1(

TDTCRFFCR

−−

=

D=present value of depreciation (MACRS), T=total tax rate

H2A Delivery

Financial Analysis (cont.)

• Capital multiplied by FCR; product added to sum of annual costs (labor, utilities, other O&M) – Gives required revenue

• Required revenues calculated then divided by actual hydrogen throughput in a year for component– $/kg of H2 cost

H2A Delivery

Compressed Gas Truck Delivery

• Calculations assume trailer is dropped off at station

• Tab designed based on one tractor and enough trailers to maximize tractor utilization

• Analysis period = 20 yrs

H2A Delivery

Compressed Gas Truck (cont.)• Trailer assumptions (H2A KIC):

– Max P = 2,640 psig, Min P = 135 psig– Super Jumbo trailer holds 9 tubes, total of 340 kg

of H2– Lifetime - 20 yrs, MACRS Schedule - 5 yrs– Capital Cost - $165,000 (year 2005 dollars)

• Tractor assumptions:– Avg. speed – 50 km/hr (30 mph)– Fuel economy – 2.6 km/L (6 mpg)– Lifetime - 5 yrs; MACRS schedule – 5 yrs– Capital Cost - $165,000 (year 2005 dollars)

• No overnight coach

H2A Delivery

Compressed Gas Truck Cost

• Scenario assumptions:– Loading time at terminal – 6 hrs– Drop-off/Pick-up time – 2 hrs

• Roundtrip Delivery Distance – 100 km– H2 Station demand – 100 kg/day– Trailers required – 16

• Compressed Gas Truck Portion of Delivered H2 Cost– $1.44/kg of hydrogen– $0.83/kg for capital, $0.04/kg for fuel, $0.56 for

other (includes labor)

H2A Delivery

Compressed Gas Truck: Delivery Distance vs. Cost

$0.00

$0.50

$1.00

$1.50

$2.00

$2.50

0 100 200 300 400 500

Roundtrip Distance (km)

Hyd

roge

n Co

st ($

/kg)

Assumptions:

Maximum Pressure: 180 atm

Station Demand: 100 kg/day

H2A Delivery

Compressed Gas Truck: Maximum Pressure vs. Cost

$0.00$0.20$0.40$0.60$0.80$1.00$1.20$1.40$1.60$1.80$2.00

0 2000 4000 6000 8000 10000 12000

Maximum Trailer Pressure (psia)

Hydr

ogen

Cos

t ($/

kg)

Assumptions:

Delivery Distance: 100 km

Station Demand: 100 kg/day

H2A Delivery

Spreadsheet Demonstration

H2A Delivery

Liquid H2 Truck Delivery

• Design based upon 1 tractor and 1 trailer– Flexibility to specify 1,

2 or 3 stops• Storage assumed to

exist at delivery site• Same tractor/scenario

assumptions as gas truck delivery

H2A Delivery

LH2 Truck Delivery Cost• Trailer assumptions:

– Capacity – 17,000 gall (3,800 kg of H2)– Unloading/Loading losses – 6%– Lifetime – 20 yrs; MACRS Depreciation – 5 yrs– Capital cost - $715,000 (year 2005 dollars)

• Roundtrip Delivery Distance – 100 km– H2 Station demand – 1,500 kg/day– Number of stops – 2 per trip

• LH2 Truck Portion of Delivered H2 Cost– $0.24/kg of hydrogen– $0.13/kg for capital, <$0.01/kg for fuel, $0.11 for

other (includes labor)

H2A DeliveryCompressor (Single, Multi-stage

and Forecourt)• Based on one compressor• User can input adiabatic efficiency and have

power req. calculated, or enter power required in kWh/kg of H2

• Analysis period - 20 yrs• Compressor assumptions:

– 90% availability– Cp/Cv – 1.4 (for H2 compression)– Adiabatic efficiency – 70%– Lifetime – 5 yrs; MACRS Schedule – 5 yrs

From American Gas Compression Services website

H2A DeliveryNG Compressor Station Construction Costs

(2005$)

y = 40094x0.6674

R2 = 0.855

$0

$5,000,000

$10,000,000

$15,000,000

$20,000,000

$25,000,000

$30,000,000

$35,000,000

0 5,000 10,000 15,000 20,000

Compressor Power (kW)

Cap

ital C

ost (

$)

Data from Oil and Gas Journal Report on Pipelines, 2000

H2A Delivery

Capital cost of Large H2 compressors versus power (kW)

0

10

20

30

40

50

60

70

80

0 5000 10000 15000 20000 25000 30000 35000

COmpressor power (kW)

Cap

ital C

ost (

mill

ion

2000

$)

DTI (APCI) -multistageSimbeck (single stage)H2A fit to OGJ

H2A Delivery

Compressor Cost• Larger scale compressor

– Design capacity – 300,000 kg/day– Inlet pressure – 20 atm (295 psia)– Outlet pressure – 70 atm (1,030 psia)– Pressure ratio – 1.7, 3-stages

• Compressor Portion of Delivered H2 Cost– $0.12/kg of hydrogen ($21MM capital)– $0.06/kg for capital, $0.05/kg for energy,

$0.01 for other (includes labor)

H2A Delivery

Forecourt Compressor• Design parameters

– Design capacity – 1,500 kg/day– Inlet pressure – 20 atm (295 psia)– Outlet pressure – 340 atm (5,000 psia)– Pressure ratio – 2.5, 4-stages

• Forecourt Compressor Portion of Delivered H2 Cost (2 compressors)– $0.54/kg of hydrogen ($600,000 capital)– $0.35/kg for capital, $0.13/kg for energy,

$0.06 for other (includes labor)

H2A Delivery

Pipeline Delivery

• Tab does not design pipeline network for the user– Asks for

transmission, trunk and distribution details

From Praxair 2003 Annual Report

H2A Delivery

Pipeline Delivery

• Can calculate diameter or outlet pressure– Calculations based on Panhandle B

Equation

EZLTdPP

PTq

mmsc

scsc

51.0961.0

961.422

2102.1 ])([)(737γ−

=

qsc=flowrate (scfm); Tsc=temp at STP (R); Psc=press at STP.; P1=inlet press. (psia); P2=outlet press. (psia); d=diameter (in); γ=gas relative density; L=length (mi); Tm=mean temp. (R); Zm=mean compressibility factor; E=pipeline efficiency

H2A DeliveryPlot of Pipeline Material Cost vs. Pipeline Diameter

y = 572640x1.786

$0$100,000$200,000$300,000$400,000$500,000$600,000$700,000

0.00 0.20 0.40 0.60 0.80 1.00 1.20

Pipeline Diameter (m)

Pipe

line

Mat

eria

l Cos

t ($

/km

)

Data from Oil and Gas Journal Report on Pipelines, 2003

Plot of Pipeline Labor Cost vs. Pipeline Diameter

y = 722512x

$0

$200,000

$400,000

$600,000

$800,000

$1,000,000

0.00 0.20 0.40 0.60 0.80 1.00 1.20

Pipeline Diameter (m)

Pipe

line

Labo

r Cos

t ($

/km

)

H2A DeliveryPlot of Miscellaneous Pipeline Costs vs. Pipeline

Diameter

y = 228309x + 61966

$0

$100,000

$200,000

$300,000

$400,000

0.00 0.20 0.40 0.60 0.80 1.00 1.20

Pipeline Diameter (m)

Mis

cella

neou

s Pi

pelin

e C

osts

($/k

m)

Data from Oil and Gas Journal Report on Pipelines, 2003

Plot of Pipeline Right of Way Costs vs. Pipeline Diameter

y = 36451x + 21436

$0$20,000$40,000$60,000$80,000

$100,000$120,000$140,000

0.00 0.20 0.40 0.60 0.80 1.00 1.20

Pipeline Diameter (m)

Pipe

line

Rig

ht o

f Way

C

osts

($/k

m)

H2A Delivery

Pipeline: Plot of Total H2 Cost (Trans. and Trunk Dist.) vs. Design Capacity

$0.00$0.10$0.20$0.30$0.40$0.50$0.60$0.70$0.80

50,000 100,000 250,000 500,000

Design Hydrogen Capacity (kg/day)

Hydr

ogen

Cos

t ($/

kg)

Total H2 CostTransmission CostTrunk/Dist. Cost

Assumptions:

Pipeline Set-up: 100 mi Transmission, 5x5 mi trunk lines, 20x2 mi distribution lines

Diameters sized based upon pressure drops: Transmission (1,000 –700 psia), trunk (600-450 psia), distribution (400-300 psia)

H2A Delivery

Pipeline: Plot of Cost vs. Flowrate for Several Transmission Pipeline Lengths

$0.01

$0.10

$1.00

$10.00

$100.00

0 500,000 1,000,000 1,500,000 2,000,000 2,500,000

Flowrate (kg/day)

Hydr

ogen

Cos

t ($/

kg)

50 miles100 miles200 miles500 miles1,000 miles

Assumptions:

Pipeline diameter for each length calculated at maximum flowrate, assuming pressure drop of 300 psi (1,000 – 700 psi)

Diameters: 50 mi (20 in), 100 mi (23 in), 200 mi (24 in), 500 mi (32 in), 1,000 (37 in)

H2A Delivery

H2A Delivery

Liquefier

• Allows user to specify power requirement (kWh/kg of H2) or have power calculated

• Analysis period – 20 yrs

From Praxair 2003 Annual Report

H2A Delivery

Plot of Liquefier Cost vs. Capacity y = 8.5618x0.523

R2 = 0.9328

$0.0

$50.0

$100.0

$150.0

$200.0

$250.0

0 100 200 300 400 500

Liquefier Capacity (tonnes/day)

Liqu

efie

r Cos

t ($M

M,

Ref

eren

ce Y

ear

$)

Data from Taylor, 1986; Simbeck, 2002; DTI, 1997

H2A Delivery

Plot of Actual Liquefaction Energy Requirement vs. Liquefier Capacity

y = 85959x-0.1951

R2 = 0.9816

0

50000

100000

150000

200000

250000

0.01 0.1 1 10 100 1000

Liquefier Capacity (tonnes/day)

Act

ual L

ique

fier E

nerg

y R

equi

rem

ent (

MJ/

tonn

e of

H

2)

Data from Bossel et al., 2003

H2A Delivery

Liquefier – Cost

• Liquefier assumptions:– Design flowrate – 50,000 kg/day– Availability – 90%– Lifetime – 20 yrs; MACRS schedule – 15 yrs.

• Liquefier Portion of Delivered H2 Cost– $2.27/kg of hydrogen ($66MM capital)– $1.01/kg for capital, $0.95/kg for energy, $0.31 for

other (includes labor)

H2A Delivery

Liquefier: Plot of Capacity vs. Hydrogen Cost/Energy Cost

0

1

2

3

4

5

6

0 20000 40000 60000 80000 100000 120000

Liquefier Capacity (kg/day)

Hydr

ogen

Cos

t ($/

kg)

Total Liquefier CostEnergy Cost

H2A Delivery

Bulk Liquid Hydrogen Storage

• Allows user to size storage based on system throughput and days of storage, or system throughput and tank size

• Analysis period –20 years

H2A Delivery

Plot of Liquid H2 Storage Cost vs. Capacity y = 0.0321x + 0.8174

R2 = 0.8638

0

5

10

15

20

0 100 200 300 400 500

Storage Capacity (tonnes)

Stor

age

Cos

t ($M

M, Y

ear

2005

$)

Data from Taylor, 1986; Simbeck, 2002; DTI, 1997

H2A Delivery

Bulk Liquid Hydrogen Storage

• Liquid Storage:– Design capacity – 50,000 kg/day, 2 days storage– Useable portion of tank – 90%– Boil-off – 0.25%/day– Lifetime – 20 yrs; MACRS Schedule – 7 yrs.

• Bulk Liquid Hydrogen Storage Portion of Delivered H2 Cost– $0.08/kg of hydrogen ($4MM capital)– $0.06/kg for capital, $0.02 for other (includes

labor)

H2A Delivery

Compressed Gas Storage (Tubes)

• Allows user to size storage based on system throughput and days of storage, or system throughput and tank size

• Analysis period –20 yrs

From Linde website

H2A Delivery

Compressed Gas Storage - Costs

• Key assumptions:– Design Flowrate – 50,000 kg/day, 2 days storage– Max. Pressure – 415 atm (6000 psia)– Min. Pressure – 10 atm (150 psia)– Lifetime – 20 yrs; MACRS Schedule – 15 yrs.– Capital cost – based on quote for 358 kg tank for

$127,000, 0.8 scaling factor• Compressed Gas Storage Portion of

Delivered H2 Cost– $0.30/kg of hydrogen ($17MM capital)– $0.24/kg for capital, $0.06 for other (includes

labor)

H2A DeliveryForecourt Compressed Gas

Storage - Costs• Key assumptions:

– Design flowrate – 1,500 kg/day, 2 days storage– Max. Pressure – 415 atm (6000 psia)– Min. Pressure – 10 atm (150 psia)– Lifetime – 20 yrs; MACRS Schedule – 15 yrs.– Capital cost – based on quote for 358 kg tank for

$127,000, 0.8 scaling factor• Compressed Gas Storage Portion of

Delivered H2 Cost– $0.34/kg of hydrogen ($790,000 capital)– $0.26/kg for capital, $0.08 for other (includes

labor)

H2A Delivery

Geologic Compressed Gas Storage• Based on natural gas cavern storage

– Data came from Saltville Salt Cavern project

Geologic H2 Storage Cavern

Compressors

H2 Pipeline

H2A Delivery

Geologic Compressed Gas Storage• Based on natural gas cavern storage

– Data came from Saltville Salt Cavern project• Compressors can fill cavern/dispense to

pipeline– Designed based on greater pressure ratio– Designed to handle complete flowrate, but operate

differently• Cavern completely filled, then completely

emptied

H2A Delivery

Spreadsheet Demonstration

H2A Delivery

Geologic Compressed Gas Storage

• Key assumptions– Max. cavern pressure – 125 atm (1,850

psia)– Min. cavern pressure – 20 atm (300 psia)– Design flowrate – 500,000 kg/day, 10 days

storage– Time to fill cavern – 15 days– Time to drain cavern – 10 days

H2A DeliveryGeologic Compressed Gas

Storage - Cost• Economic parameters

– Analysis period – 20 years– Compressor lifetime – 5 yrs.; MACRS

Depreciation Schedule – 5 yrs– Cavern lifetime – 20 yrs.; MACRS Depreciation

Schedule – 15 yrs• Compressed Gas Storage Portion of

Delivered H2 Cost– $0.46/kg of hydrogen ($0.39 for

compressors/$0.07 for cavern)– $0.39/kg for capital, $0.01 for energy, $0.06 for

other (includes labor)

H2A Delivery

Geologic Storage: Refills per year vs. Hydrogen Cost

$0.00$0.50$1.00$1.50$2.00$2.50$3.00$3.50$4.00$4.50$5.00

0 2 4 6 8 10 12 14

Cavern Cycles per Year

Hyd

roge

n C

ost (

$/kg

)

Assumptions:

Time to refill – 15 days

Time to empty – 10 days

H2A Delivery

Compressed Gas Terminal

• Designed like mini-scenario• Setup

Compressed Gas Storage

Truck Loading Compressors

Storage Compressor

H2 Central Production Facility

Truck Loading

H2A Delivery

Compressed Gas Terminal (cont.)• Truck loading

compressors: 2, each designed at 75% of total terminal capacity

• Storage compressor: 1, designed for filling storage tank in 1 day

• Analysis period – 20 yrs.

H2A Delivery

Compressed Gas Terminal - Costs• Key assumptions:

– Storage press. – 6,000 psia– Compressor adiabatic efficiency – 70%– Compressor lifetime – 5 yrs– Storage lifetime - 20 yrs– Truck filling time – 6 hours

• Compressed Gas Storage Portion of Delivered H2 Cost– $0.89/kg of hydrogen ($0.64 for

compressors/$0.25 for storage)– $0.59/kg for capital, $0.16 for energy, $0.14 for

other (includes labor)

H2A Delivery

Liquid H2 Terminal

• Designed like mini-scenario• Setup

Liquid H2 Storage

Cryogenic Pumps

Liquid H2 Delivery

Truck Loading

H2A Delivery

Liquid H2 Terminal

• Liquid hydrogen pumps – 2 cryogenic pumps, each designed at 75% of the total terminal capacity

• Key assumptions:– Design flowrate – 500,000 kg/day; 5 days

of storage – Boil-off – 0.25% per day– Lifetime – 20 yrs; MACRS Schedule – 15

yrs

H2A Delivery

Liquid H2 Terminal - Costs

• Key assumptions (continued):– Truck filling time – 3 hours

• Compressed Gas Storage Portion of Delivered H2 Cost– $0.20/kg of hydrogen ($89MM capital for storage,

$7MM for low temperature pumps)– $0.15/kg for capital, $0.05 for other (includes

labor)

H2A Delivery

Conclusions

• Spreadsheet model has been developed to calculate cost, in $/kg of H2, for delivery components

• Based on fixed charge rate financial analysis method

• Meant to model static delivery cases• Base case assumptions introduced

– Detailed cost curves, based on vendor, literature data, developed for some components