20410023_BTP

TECHNO-ECONOMIC ANALYSIS FOR PRODUCTION OF
4.75 TPH GREEN HYDROGEN THROUGH WATER ELECTROLYSIS
B. TECH PROJECT REPORT

By GROUP-22
AYUSH YOGESH PATIL (20121007)

PRIYAM BANSAL (20410023)
MUKUND SHAH (20121014)
VANSHITA RAWAT (20310023)
DAKSH KUMAR (20112037)
JYOTI GHUNAWAT (20112055)
DEPARTMENT OF CHEMICAL ENGINEERING

INDIAN INSTITUTE OF TECHNOLOGY ROORKEE
ROORKEE - 247667 (INDIA)
April 2024
SUPERVISOR: PROF. B. PRASAD
Signature: ____________
CERTIFICATE
It is certified that the project entitled “Techno-Economic Analysis For Production Of 4.75 TPH Green
Hydrogen Through Water Electrolysis”, which is being submitted by Priyam Bansal(Enrolment No.
20410023), in partial fulfilment of the requirement for the award of the Degree of Bachelor of Technology in
Polymer Science and Engineering at the Indian Institute of Technology Roorkee, is a record of the candidate’s
own work carried out by him under my supervision. To the best of my knowledge, the work has not been
submitted elsewhere.
Dr. Basheshwar Prasad
Professor
Department of Chemical Engineering
Indian Institute of Technology, Roorkee
Roorkee – 247667,
India
DEPARTMENT OF CHEMICAL ENGINEERING, IIT ROORKEE

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ACKNOWLEDGEMENT
I have taken efforts in executing the project. However, it was made possible with the support and help of many
individuals and organizations.
I would like to express my gratitude towards Prof. Basheshwar Prasad for his kind co-operation and
encouragement, which helped me in the completion of this project. I am highly indebted to him for his
guidance and constant supervision, as well as for providing necessary information regarding this project and
for his support in completing this project.
My thanks and appreciation also go to my project mates and my batch mates in developing the project, who
have willingly helped with their abilities.
Priyam Bansal
Enrolment No. 20410023
B. Tech. IV Year
Department of Chemical Engineering
Indian Institute of Technology Roorkee

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ABSTRACT
This report outlines the design and feasibility of a chemical plant aimed at producing 5 tonnes per hour of
Green Hydrogen gas through the electrolysis of seawater, employing Proton Exchange Membrane
Electrolysers (PEME). Hydrogen, as a clean energy carrier, holds immense promise for various industries and
energy sectors, with seawater electrolysis offering a sustainable pathway for its production. The report
commences with a comprehensive literature review, examining diverse technologies pertinent to hydrogen
production, particularly emphasizing seawater electrolysis via PEME. It elucidates the electrochemical
reactions involved and evaluates the efficacy of PEME systems in achieving high-purity hydrogen output.
A detailed process flow diagram of the plant is provided, delineating the essential equipment such as
electrolysers, reverse osmosis unit, heat exchanger, demisters and coolers. The optimization of the plant design
is conducted using advanced simulation software to ascertain optimal operational parameters for efficient
hydrogen generation. The electrolysis process operates under specific conditions tailored for PEME efficiency,
ensuring high production rates while minimizing energy consumption.
Furthermore, the report proposes an optimal site selection based on various geographical and logistical
considerations, accompanied by a comprehensive layout of the envisaged plant. An economic analysis is also
presented, encompassing capital investment, operational costs, and revenue projections from hydrogen sales.
The findings underscore the economic viability of the plant, with a projected payback period indicating
favourable returns on investment.
In conclusion, the report underscores the potential of seawater electrolysis utilizing PEME technology as a
sustainable and economically viable means of hydrogen production. Through meticulous plant design and
economic assessment, this study provides a blueprint for the implementation of similar projects, contributing
to the advancement of clean energy initiatives and decarbonization efforts on a global scale002E

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Content
2. Summary ........................................................................................................................................................ 6
2.1 Process Summary ..................................................................................................................................... 6
2.2 Plant Location Summary .......................................................................................................................... 7
2.3 Organizational Summary.......................................................................................................................... 8
3. Project Details ................................................................................................................................................ 7
3.1 Introduction ........................................................................................................................................ 7
3.2 Project Description............................................................................................................................. 8
3.2.1 Uses and present status of hydrogen .............................................................................................. 8
3.2.2 Process Information ..................................................................................................................... 12
3.2.3 Raw Materials .............................................................................................................................. 25
3.3 Material and Energy Flow Information ........................................................................................... 37
3.4 Detailed Design of Equipment ......................................................................................................... 44
3.4.1 Process Design ............................................................................................................................. 44
3.4.2 Mechanical Design....................................................................................................................... 61
3.4.3 Mechanical Drawing .................................................................................................................... 67
3.4.4 Specifications of process equipment ............................................................................................ 68
3.4.5 Engineering problems and their possible remedies ..................................................................... 71
3.5 Material Storage & Handling Facilities ........................................................................................... 74
3.5.1 H2 (Hydrogen) ............................................................................................................................. 74
3.5.2 Seawater ....................................................................................................................................... 77
3.5.3 Oxygen ......................................................................................................................................... 78
3.6 Process Instrumentation & Control and Safety Aspects .................................................................. 79
4. Environmental Protection & Energy Conservation ..................................................................................... 81
4.1 Environmental Aspects .................................................................................................................... 81
4.1.1 Air Pollution................................................................................................................................. 81
4.1.2 Liquid Effluents ........................................................................................................................... 81

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4.1.3 Solids Disposal............................................................................................................................. 82
4.1.4 Noise Pollution............................................................................................................................. 85
4.2 Energy Conservation ........................................................................................................................ 86
5. Plant Utilities ............................................................................................................................................... 87
5.1 Air .................................................................................................................................................... 87
5.1.1 Air for Process and Instrumentation: ........................................................................................... 87
5.2 Heat Transfer Media ........................................................................................................................ 89
5.2.1 Steam as a Heat Transfer Medium ............................................................................................... 89
5.2.2 Steam Generation System ............................................................................................................ 89
5.3 Water ................................................................................................................................................ 90
5.3.1 Process and General Water Requirements and Standards ............................................................ 90
5.3.2 Water Treatment and Storage Facilities: ...................................................................................... 91
5.4 Refrigeration .................................................................................................................................... 93
5.5 Electricity/Power.............................................................................................................................. 94
6. Organizational Structure and Manpower Requirement ............................................................................... 94
6.1 Organizational Structure ................................................................................................................ 894
7. Market Prospects ........................................................................................................................................ 103
7.1 A brief analysis of demand and supply of green hydrogen............................................................ 103
7.2 Present production capacity/licenced capacity in the country giving the status of the production 104
7.3 Marketing set-up and area of consumption .................................................................................... 104
8. Site Selection & Project Layout ................................................................................................................. 106
9. Economic Evaluation & Profitability of the Project .................................................................................. 109
10. References ................................................................................................................................................ 120

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2. Summary
2.1 Process Summary
The project focuses on the development and implementation of green hydrogen production using Proton
Exchange Membrane (PEM) water electrolysis powered by renewable energy sources using seawater as the
feedstock. By harnessing renewable energy such as solar, wind, or hydroelectric power, we aim to electrolyze
water to generate hydrogen gas without emitting greenhouse gases. The PEM electrolyser technology
selectively allows protons to pass through a membrane, facilitating the separation of hydrogen and oxygen
gases. The use of seawater offers a sustainable and readily available resource for hydrogen production,
minimizing freshwater consumption and environmental impact. The produced green hydrogen holds promise
as a clean energy carrier for various applications, including transportation and industrial processes,
contributing to decarbonization efforts and combating climate change. Our project seeks to optimize the
efficiency and scalability of PEM electrolysis systems, considering factors such as renewable energy
integration, cost-effectiveness, and environmental sustainability. Through this endeavour, we aim to accelerate
the transition towards a low-carbon energy future while promoting innovation and economic growth in the
green hydrogen sector.
2.2 Plant Location Summary

For any plants' economic feasibility, choosing the site location and layout is essential, keeping the
governments' policies, subsidies, transport, raw materials availability, and market accessibility in mind. Our
report expresses why choosing Jamnagar, Gujarat is the best fit for our plant.
2.3 Organizational Summary

It is well believed that a company is only as good as its employees, therefore, it was fundamental for us to
choose the best possible workforce that would do the job, keeping the expenses as low as possible. Given
below is the organization chart

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3. Project Details
3.1 Introduction
Hydrogen is more than an element it is a promising solution to one of the greatest challenges in the
renewable energy sector since it is zero-emission at the point of use and can be produced without
emissions. Hydrogen fuel cells are widely regarded as a practical new technology that can decarbonize
many industries and sectors. The hydrogen economy is progressing. In the last 10 years, there has been
an urgency around climate change that has put hydrogen back on the agenda.

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Hydrogen will be a key factor to achieving an energy transition. We can use it to decarbonize many other
sectors that can't be decarbonized with battery technology, particularly heavy transportation.
This project, titled “Techno-economic analysis for production of 4.75 TPH green hydrogen through water
electrolysis" aims to leverage the boundless potential of the world's oceans, our planet's most abundant
resource, for the generation of hydrogen as a clean and renewable energy source.
3.2 Project Description

3.2.1 Uses and present status of hydrogen
Important uses of hydrogen:
 Ammonia Synthesis and Fertilizer Production: Hydrogen is crucial for synthesizing ammonia
and manufacturing nitrogenous fertilizers.
 Hydrogenation of Vegetable Oils: Used in the hydrogenation process to produce fats like
Vanaspati from unsaturated vegetable oils.
 Organic Compound Synthesis: Hydrogen is used in the manufacture of various organic
compounds such as methanol.

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 Petroleum Refining (Hydrocracking): Plays a key role in hydrocracking processes to produce
gasoline and diesel from petroleum, also used to remove sulphur contaminants.
 Hydrogen Chloride Production: Hydrogen is used to prepare hydrogen chloride, an important
chemical.
 Metallurgical Processes: Hydrogen can reduce metal oxides to produce metals in metallurgical
processes.
 Rocket Fuel: Widely used as rocket fuel in space research and exploration.
 Hydrogen Fuel Cells: Being explored as an alternative energy source in automotive
applications like hydrogen fuel cell vehicles.
 Low-Temperature Production: Liquid hydrogen is utilized in laboratories to achieve very low
temperatures.
 Hydrogen Peroxide Production: Used in the production of hydrogen peroxide (H2O2).
 Therapeutic Gas: Studied for potential therapeutic applications in treating various diseases.
 Public Transportation: Hydrogen fuel cells are considered for buses and trains to reduce
emissions.
 Atomic Hydrogen Welding: A specialized welding process using hydrogen as a shielding
atmosphere for welding refractory metals.
 Leak Detection: Used in manufacturing plants for leak detection due to its low environmental
impact compared to other gases.
 Gas Chromatography: Used as a carrier phase in gas chromatography for separating volatile
substances.
 Hydrogen's versatility makes it a vital component in various industries, from agriculture and
energy to manufacturing and transportation.

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3.2.2 Process Information
3.2.2.1 Available processes to produce the product with brief description
Overview of the status of technologies and schemes related to the electrolysis of seawater and various
electrolysis methods, including Alkaline Electrolysis (AE), Proton Exchange Membrane Electrolysis (PEME),
and Solid Oxide Electrolysis (SOE) are given below.

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Direct Electrolysis of Seawater (DES):
 Status: Electrolysis of seawater is a process that can simultaneously produce hydrogen and desalinate
seawater. The technology was being researched and developed as a sustainable way to address both
the growing demand for clean hydrogen and freshwater shortages, especially in arid regions.
 Challenges: While the concept shows promise, challenges include high energy requirements, cost-
effectiveness, and the development of efficient catalysts for seawater electrolysis.
 Applications: DES has the potential to provide a sustainable source of hydrogen for various
applications, including fuel cells, while addressing water scarcity issues through desalination.

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Alkaline Electrolysis (AE):
 Status: Alkaline electrolysis has been a mature and well-established technology for many years. It
involves the use of alkaline electrolyte solutions like potassium hydroxide (KOH) or sodium hydroxide
(NaOH) to facilitate the splitting of water into hydrogen and oxygen.
 Advancements: Research has been focused on improving the efficiency and reducing the cost of
alkaline electrolysis systems, making them more competitive in the growing green hydrogen market.
 Applications: AE is commonly used for industrial hydrogen production, energy storage, and in some
renewable energy integration projects.

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Proton Exchange Membrane Electrolysis (PEME):
 Status: PEME technology has gained significant attention due to its high efficiency and rapid response
times. It utilizes a proton-exchange membrane to separate hydrogen and oxygen and is well-suited for
small to medium-scale hydrogen production.
 Advancements: PEME systems have seen continuous advancements, with improved membrane
materials, catalysts, and system designs. These developments aim to enhance efficiency and reduce
costs.
 Applications: PEME is being used in various applications, including hydrogen fuelling stations and
renewable energy storage.

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Solid Oxide Electrolysis (SOE):
 Status: SOE is a developing technology designed to operate at high temperatures, typically exceeding
600°C. It employs a solid oxide electrolyte to facilitate the electrolysis of steam (H2O) into hydrogen
(H2) and oxygen (O2). The technology's current status involves ongoing research and experimentation
as it progresses toward wider implementation.
 Advancements: Recent advancements in SOE have showcased its potential for high efficiency and the
ability to harness waste heat. Research and development efforts are focused on enhancing the durability
of SOE systems and reducing their operating temperatures. These improvements aim to make SOE
more practical and economically viable for various applications.
 Applications: SOE holds promise for integration with high-temperature processes, such as industrial
heat, enabling the production of hydrogen. It is actively explored for applications in the production of
green hydrogen, contributing to the transition towards more sustainable and environmentally friendly
hydrogen production methods. The versatility of SOE makes it a candidate for integration into a range
of processes that require high-temperature electrolysis.

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The success of various electrolysis methods often involves a combination of various factors, such as cost-
effectiveness, efficiency, scalability, etc. and advancements in technology and supportive policies can
further enhance their viability and adoption.
Process Details
 Working Principle:
The PEM electrolyser operates as a solid oxide hydrogen production cell, utilizing deionized water as the
electrolyzed raw material. The DC current density falls within the range of 10000A/m2 to 20000A/m2.
Distinguished by its operational temperature between 50°C and 80°C, pressure below 5 MPa, and a smaller
volume compared to alkaline electrolysers, the PEM electrolyser is adaptable to varying pressures. A key
feature involves the utilization of a thin film-electrode assembly, commonly referred to as a membrane
electrode, establishing a zero-pole spacing. The separator, comprised of a Nafion membrane, becomes
strongly acidic post-immersion in water. The anode catalyst and cathode catalyst are affixed to both sides
of the separator through electroless plating or hot pressing.
 PEM Electrolysis Hydrogen Production Process:

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The PEM hydrogen production system comprises a PEM hydrogen production unit, a control system, and
a DC power supply. In comparison to alkaline water hydrogen production systems, the PEM hydrogen
production system boasts simplicity. The gas aftertreatment device is relatively compact, eliminating the
need for a specialized alkali tank. Additionally, the water tank serves the dual purpose of being utilized as
an oxygen separator.
Upon initiating the equipment, the water tank is replenished to the set liquid level, and the circulation
pump is activated for circulation. The water level in the hydrogen separator is monitored until it reaches
the designated position. Once the liquid levels stabilize in both the water tank and the hydrogen separator,
the DC power source is activated, initiating the electrolysis process within the PEM electrolytic cell.
Oxygen and water undergo separation into the water tank, with subsequent filtration of oxygen through a
molecular sieve for discharge.
 PEM hydrogen production process flow sheet is shown above.
The reactions that happen inside a PEME cell are the following:
Anode: H2O(l) → 2H+(aq.) + 2e- + O2 (g)
Cathode: 2H+(aq.) + 2e- → H2 (g)

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Overall: H2O(l) → O2 (g) + H2 (g)
 Hydrogen Production and Separator Operation:
Hydrogen, accompanied by a small water fraction, enters the hydrogen separator, where the hydrogen gas
undergoes further treatment via a molecular sieve. As the water in the hydrogen separator attains a specific
liquid level, a portion of it flows into the water tank. Throughout operation, electrolysis induces a reduction
in moisture content, necessitating precise control over the water replenishment volume. Moreover, the
PEM electrolyser has the capability to operate under differential pressure, eliminating the need for gradual
regulation during startup, as required in alkaline water hydrogen systems. The regulating valve pressure
can be directly set to the specified level, enabling equipment stabilization within a brief 15-minute
timeframe.
3.2.2.2 Techno-economic appraisal of alternative processes/schemes

Various technologies exist for hydrogen production, such as reforming, decomposition, and fossil fuel-
based hydrolysis. The annual demand for hydrogen is around four billion tons, with 95% of it currently
coming from fossil fuels, a process that also produces CO2 emissions.
Production of hydrogen is mainly done using either fossil fuels or through RS, which is presented in
Figure.

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However, there's a promising alternative: water electrolysis powered by renewable energy sources.
This method has the potential to scale up hydrogen production while producing zero CO2 emissions.
Electrolysis technologies have distinctive characteristics, as summarised in Table 1.
Storing excess solar and wind energy as hydrogen holds significant potential. Hydrogen generated
through water electrolysis boasts high purity (99.9%) and can serve as a crucial component in various
industrial processes.

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3.2.2.3 Status of Global Hydrogen Production
In 2020, despite the challenges posed by the COVID-19 pandemic, hydrogen production technologies
remained resilient and robust, according to the International Energy Agency (IEA). This year marked
a significant milestone, characterised by a record level of policy actions and the expansion of low-
carbon production efforts. Notably, ten governments worldwide adopted hydrogen strategies. During
this period, approximately 70 MW of electrolysis capacity was installed, doubling the previous year's
record. Additionally, two hydrogen production facilities employing Carbon Capture, Utilization, and
Storage (CCUS) technology became operational, leading to a 15% increase in production capacity.
The demand for hydrogen has steadily increased over the years, with a substantial portion of produced
hydrogen (51%) being utilised in ammonia production. Oil refining accounts for about 31% of its
usage, while 10% is dedicated to methanol production, and the remaining 8% serves various other
purposes.

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3.2.2.4 Selection of technology/scheme
Basis of selection, details of the selected process, including flow sheet the alkaline water (ALK)
electrolyser is one of the most established and widespread technologies, capturing a 70% share of the
green hydrogen market. Conversely, the polymer electrolyte membrane (PEM) electrolysis, depicted
in Figure 1, is gaining popularity among significant electrolyser manufacturers. It produces higher-
quality hydrogen and can operate intermittently. However, it comes at a higher cost and offers a lower
production rate than ALK. Meanwhile, the solid oxide electrolyser is still in the research and
development phase. Although it's highly efficient and cost-effective, it lacks quick startup capabilities.

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1
Anode: O( ) → O ( ) + 2e
2
Cathode: H O( ) + 2e → H ( ) + O( )
Overall: H O( ) → O ( ) +H ( )

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This process hinges on generating hydrogen using photovoltaic generation when the sun is shining and
drawing power from the grid when needed, like on cloudy days or at night. The electrolyser module is
crucial in this process, taking in the required amounts of water and electricity for hydrogen production,
compression, and storage. The final step involves transferring the hydrogen for export. Figure 4
illustrates a representative scheme for each optimized module.

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3.2.2.5 Source of knowhow of selected process/technology
Hydrogen is the most efficient energy carrier. Hydrogen can be obtained from different sources of raw
materials including water. Among many hydrogen production methods, eco-friendly and high purity
of hydrogen can be obtained by water electrolysis. However, In terms of sustainability and
environmental impact, PEM water electrolysis was considered as most promising techniques for high
pure efficient hydrogen production from renewable energy sources and emits only oxygen as
byproduct without any carbon emissions.
Moreover, the produced hydrogen (H2) and oxygen (O2) directly used for fuel cell and industrial
applications. However, overall water splitting resulting in only 4% of global industrial hydrogen being
produced by electrolysis of water, mainly due to the economic issues. Nowadays, increased the desire
production of green hydrogen has increased the interest on PEM water electrolysis.
Thus, the considerable research has been completed recently in the development of cost effective
electrocatalysts for PEM water electrolysis. In this present review, we discussed about the recent
developments in the PEM water electrolysis including high performance and low cost HER and OER
electrocatalysts and their challenges new and old related to electrocatalysts and PEM cell components
also addressed.
Moreover, the continuously escalating global energy demand and the finite reserves of fossil fuels,
coupled with concerns regarding sustainability and environmental impact, necessitate the development
of new energy paradigms devoid of carbon emissions. Presently, there is a growing emphasis on
environmentally friendly energy strategies that have the potential to supplant current fossil fuel-based
energy production. This transition can be facilitated by producing hydrogen from renewable water
sources. Among the various methods of hydrogen production, water electrolysis stands out as an eco-
friendly approach, capable of yielding high-purity hydrogen (99.999%). This process involves the
electrolysis of water to generate pure hydrogen and oxygen. The fundamental reaction is elucidated as
follows:

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3.2.3 Raw Materials
3.2.3.1 Detailed specifications
Seawater:
Sea water, derived from seas or oceans, typically exhibits a salinity of approximately 3.5% (35 g/L, 35
ppt, 600 mM) in the world's oceans. This indicates that each kilogram (roughly equivalent to one liter
in volume) of sea water contains around 35 grams (1.2 oz) of dissolved salts, primarily sodium (Na+)
and chloride (Cl−) ions. With an average surface density of 1.025 kg/L, sea water surpasses both fresh
water and pure water (with a density of 1.0 kg/L at 4 °C or 39 °F) in density due to the increased mass
caused by dissolved salts, which outweighs the volume proportionally. As the concentration of salt
rises, the freezing point of sea water decreases, typically freezing at about −2 °C (28 °F) under typical
salinity conditions. Notably, the coldest recorded liquid sea water was discovered in 2010 beneath an
Antarctic glacier, registering a temperature of −2.6 °C (27.3 °F).
Seawater is abundant along India's extensive coastline encompassing states like Gujarat, Maharashtra,
Goa, Karnataka, Kerala, Tamil Nadu, Andhra Pradesh, Odisha, and West Bengal, as well as the
Andaman and Nicobar Islands, plays a pivotal role in various natural processes.

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 Composition:
The Indian Ocean is the world's third-largest ocean, covering 19.8 % of the water on the Earth's surface.
In contrast to the Pacific and Atlantic oceans, it does not stretch from pole to pole but is enclosed on
three sides by major landmasses.

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 Water as an Electrolyte:
In proton exchange membrane (PEM) water electrolysis, water undergoes electrochemical splitting
into hydrogen and oxygen at their respective electrodes: hydrogen forms at the cathode, while oxygen
forms at the anode. This process involves water being pumped to the anode, where it separates into
oxygen (O2), protons (H+), and electrons (e−). The protons then migrate through a proton-conducting
membrane to reach the cathode. Meanwhile, the electrons flow out of the anode through an external
power circuit, supplying the driving force (cell voltage) for the reaction. On the cathode side, the
protons and electrons recombine to generate hydrogen, following the mechanism illustrated below.

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Proton Exchange Membrane (PEM):
The concept of PEM water electrolysis was first conceived by Grubb in the early 1950s, with
subsequent development by General Electric Co. in 1966 to address limitations of alkaline water
electrolysis. PEM water electrolysis technology bears resemblance to PEM fuel cell technology,
utilizing solid polysulfonated membranes (such as Nafion® and fumapem®) as electrolytes (proton
conductors).
These proton exchange membranes offer numerous advantages, including reduced gas permeability,
high proton conductivity (approximately 0.1 ± 0.02 S cm−1), thinner profiles (ranging from 20 to 300
µm), and suitability for high-pressure operations. From a sustainability and environmental perspective,
PEM water electrolysis emerges as a favorable method for converting renewable energy into high-
purity hydrogen.

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Another noteworthy aspect of PEM water electrolysis is its compact design, high current density
(exceeding 2 A cm−2), high efficiency, rapid response, small footprint, operation at lower temperatures
(20–80 °C), and production of ultrapure hydrogen, with oxygen generated as a byproduct. Moreover,
the ease of balancing PEM electrolysis plants enhances their appeal for industrial applications. The
cutting-edge electrocatalysts for PEM electrolysis predominantly feature noble metals such as Pt/Pd
for the hydrogen evolution reaction (HER) at the cathode and IrO2/RuO2 for the oxygen evolution
reaction (OER) at the anode, albeit at a higher cost compared to alkaline water electrolysis. Hence, a
primary challenge in PEM water electrolysis lies in reducing production costs while maintaining high
efficiency. Substantial research efforts have been dedicated to enhancing PEM water electrolysis
components, positioning this technology on the brink of commercialization.
The primary components of a PEM water electrolysis cell include membrane electrode assemblies
(MEAs), current collectors (gas diffusion layers), and separator plates. A typical assembly of a PEM
water electrolysis cell is depicted below. However, the MEA serves as the core of the electrolysis cell,
dividing it into two half-cells: the anode and the cathode.

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Fig. (a) Overview of typical PEM water electrolyzier (b) PEM cell stack (c) Cell components; 1-
Bipolar plate, 2-Anode current collector, 3-MEA, 4-Cathode current collector.
Electrodes
Anode:
 Function: At the anode, water molecules undergo oxidation, releasing oxygen gas (O2) and protons
(H+).
 Properties: Requires high electrocatalytic activity for the oxygen evolution reaction (OER), stability
under acidic conditions, and efficient gas diffusion to facilitate oxygen release.
 Material: Commonly utilized materials include IrO2 and RuO2 due to their high catalytic activity and
stability.
Cathode:

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 Function: At the cathode, protons and electrons combine to form hydrogen gas (H2) through the
hydrogen evolution reaction (HER).
 Properties: Requires high electrocatalytic activity for the HER, stability under acidic conditions, and
efficient gas diffusion for hydrogen release.
 Material: Typically employs platinum-based catalysts (e.g., Pt/Pd) due to their high activity for
hydrogen evolution.
 Function: Serves as a solid electrolyte, facilitating the transport of protons from the anode to the
cathode.
 Properties: Requires high proton conductivity, low gas permeability, chemical stability under acidic
conditions, and mechanical durability.
 Materials: Commonly used membranes include perfluorosulfonic acid membranes such as Nafion®
and hydrocarbon-based membranes like sulfonated polyether ether ketone (SPEEK).
Electricity and associated Parameters
Parameters suitable for PEME
 Voltage: PEM electrolyzers typically operate at low voltages, commonly ranging from 1.5 to 2.2 volts,
depending on the specific electrolysis conditions and cell design. This ensures efficient electrolysis
while minimizing energy consumption.
 Current Density: High current density is desirable for maximizing hydrogen production rates in PEM
electrolyzers. Typical values range from 1 to 3 amperes per square centimeter (A/cm²), with
advancements aiming for even higher values to enhance productivity.
 Power Supply: PEM electrolyzers require a stable and controllable power supply to maintain optimal
operating conditions. Direct current (DC) power sources are commonly used, with precise voltage and
current regulation capabilities.
 Electrical Efficiency: Maximizing electrical efficiency is crucial for minimizing energy losses during
electrolysis. PEM electrolyzers aim for high Faradaic efficiency, ensuring that the majority of supplied
electrical energy is converted into chemical energy stored in the produced hydrogen.

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 Temperature: PEM electrolyzers operate efficiently at moderate temperatures, typically in the range of
20 to 80 degrees Celsius. Operating at elevated temperatures can enhance reaction kinetics and proton
conductivity, improving overall electrolyzer performance.
 Pressure: Applying elevated pressure to the electrolysis process can enhance hydrogen production rates
and improve overall system efficiency. PEM electrolyzers often operate at pressures ranging from 1 to
30 bar, with higher pressures resulting in increased gas solubility and transport rates.
3.2.3.2 Requirement of raw materials and basic assumptions made in computing the raw material
requirement
Assumptions:
 Seawater Source: The Plant has ready access to sea water as the location is decided based on
the availability of raw materials.
 PEME Efficiency: For calculation purposes, we make the assumption that PEME devices
convert water into hydrogen gas at an efficiency rate of 80% and the unreacted water is
recycled.
 Electricity Source: We have availability of green energy in the form of electricity from the
installed solar panels in sufficient amount.
 No Losses: We have considered all losses due to heat dissipation and other sources as negligible
for calculation purposes.
 Capacity: The Plant produces 4.75 TPH Hydrogen through water electrolysis that will be
directly sold to the industries and end customers.
Raw Material Requirement:

To ascertain the total seawater volume needed to produce 5 tons of hydrogen per hour, the following
calculation is applied:
Total Seawater Requirement (in tons per hour) = 111.68

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The calculations for this conversion are done in the mass balance sheet with assuming efficiencies
for RO unit (pre-treatment), PEME (electrolyser) based on literature review, and taking into
consideration the water conversion efficiency of the electrolyser
3.2.3.3 Availability: Indigenous/Imported

Seawater:
An abundant resource, seawater can be found all along India's lengthy coastline, which includes states
like Gujarat, Maharashtra, Goa, Karnataka, Kerala, Tamil Nadu, Andhra Pradesh, Odisha, West
Bengal, and the Andaman and Nicobar Islands. This makes seawater an easily available and native raw
material for India's PEME-based hydrogen generation.
Because seawater is abundant in the area, it is rarely necessary to import it as a raw material. On the
other hand, difficulties could appear if a facility for producing hydrogen is located far inland or in an
area with limited access to saltwater. Logistical challenges in these situations may lead to the
investigation of other water sources.

Proton Exchange Membrane (PEM) was estimated to have a market size of USD 6.56 billion in 2021
and USD 7.66 billion in 2022. It is expected to grow at a Compound Annual Growth Rate (CAGR) of
16.8% over the forecast period (2023–2030) to reach a value of USD 26.54 billion by 2030. The
expected increase is ascribed to the growing need for alternate energy sources and the growing
apprehensions over environmental contamination.
The United States, Canada, Mexico, Europe (Germany, UK, France, Italy, Russia, Turkey), Asia-
Pacific (China, Japan, Korea, India, Australia, Indonesia, Thailand, Philippines, Malaysia, Vietnam),
South America (Brazil, Argentina, Columbia), and the Middle East and Africa (Saudi Arabia, UAE,
Egypt, Nigeria, South Africa) are the key regions in the PEM market.
In 2021, the top five global manufacturers of PEMs, including Protonex, LEANCAT, Asahi Kasei,
Treadwell, and DuPont, collectively accounted for a substantial share of the market's revenue.

33
Electrodes
 Cathode Electrode Materials:
 Nickel-Molybdenum (Ni-Mo) Alloys
Ni-Mo alloys, which are made of nickel and molybdenum, may be produced locally and
are more widely available. When nickel and molybdenum are sufficiently available
domestically, local manufacture of Ni-Mo alloys is a viable and economical strategy.
Although Ni-Mo alloys can be obtained from other countries, domestic manufacture is
clearly the best course of action.
 Anode Electrode Materials

 Iridium Oxide (IrO2)
India is one of the few native sources of iridium, a rare and valuable metal that is frequently
imported to guarantee a steady supply of iridium oxide for anode electrodes. Cost
ramifications and the creation of safe supply chains are two importation factors.
Electricity
There are geographic differences in India's power accessibility. The national grid provides a steady and
reliable supply of energy to many places, making electricity an indigenous raw material for the
synthesis of hydrogen. Nonetheless, circumstances can occur in which a hydrogen production plant is
located in an isolated area with insufficient electrical infrastructure, which would require the possibility
of importing electricity via generators or other alternative power supply techniques. It is important to
recognize that increased production costs and logistical challenges may result from the importing of
electricity.
3.2.3.4 Government policies for import of the raw materials

34
 Coastal Zone Management Plans: Coastal Zone Management Plans (CZMPs) are formulated by coastal
states and union territories in India to regulate and manage activities within coastal zones effectively.
These plans delineate coastal zones based on ecological, socio-economic, and developmental
considerations and prescribe regulations and guidelines for development activities. Industries
operating in coastal areas must adhere to CZMPs and obtain necessary clearances and permissions
from coastal regulatory authorities to ensure sustainable coastal development and minimize adverse
impacts on coastal environments.
 International Conventions and Treaties: India is a signatory to various international conventions and
treaties aimed at protecting the marine environment and promoting sustainable development. These
include conventions such as the United Nations Convention on the Law of the Sea (UNCLOS), the
Convention on Biological Diversity (CBD), and the Ramsar Convention on Wetlands.
 Marine Pollution Prevention: The Marine Pollution Prevention Act aims to prevent pollution of the
marine environment from ships, offshore platforms, and other marine activities. It regulates the
discharge of pollutants into the sea, including oil, chemicals, sewage, and garbage. Industries utilizing
seawater must comply with the provisions of this act to minimize their impact on marine ecosystems
and prevent pollution of coastal waters.
 Water Quality Standards by CPCB: The Central Pollution Control Board (CPCB) plays a crucial role
in regulating the discharge of treated seawater back into the ocean after industrial use. It establishes
stringent water quality standards and guidelines to govern the quality of treated effluents released into
coastal waters. These standards aim to maintain the ecological balance and integrity of marine
ecosystems by minimizing pollution and safeguarding water quality. Industries are required to treat
seawater used in their processes to meet CPCB's prescribed standards before discharge, ensuring that
the discharged effluents do not pose harm to marine life or coastal habitats.

Chemical import laws, such as those pertaining to perfluorinated sulfonic acid polymers like Nafion
for fuel cell applications in India, are regulated by the Ministry of Commerce and Industry's Directorate
General of Foreign Trade (DGFT). The main topics covered by these regulations are import-export
processes, tariffs, and customs.

35
Electrodes
The Ministry of Mines, Department of Science & Technology (DST), Ministry of Power, and other
organizations are usually in charge of critical minerals, which include elements from the Platinum
Group (platinum & iridium), nickel, and molybdenum. The Ministry of Commerce and Industry's
Directorate General of Foreign Trade (DGFT) oversees their importation. Interestingly, India raised
the total import tax on platinum from 10.75% to 15.4% lately.
Electricity
India's complete legislation governing the production, transmission, distribution, and use of electricity
is known as the Electricity Act of 2003. This Act gives state electrical regulatory commissions the
authority to establish tariffs and oversee the electricity industry. According to the Electricity Act,
qualified customers including businesses can obtain electricity from sources other than their state
distribution company (DISCOM). Industry-wide energy efficiency upgrades are required by the
Bureau of Energy Efficiency (BEE). Industries are given targets to meet about energy efficiency
through programs like Perform, Achieve, and Trade (PAT).
3.2.3.5 Prevailing prices

Hydrogen production from polymer electrolyte membrane (PEM) electrolysers is estimated to cost
approximately $5 to $6 per kilogram of H2. This assumes existing technology, with low volume
electrolyser capital costs reaching as high as $1,500 per kilowatt, and grid electricity prices ranging
from $0.05 to $0.07 per kilowatt-hour.
3.2.3.6 Testing procedures for the raw materials

 Seawater Quality Testing:
 Salinity: Verify seawater salinity compliance using ISO 8467 as a guide.
 Impurities: Test for impurities, including suspended solids, dissolved metals, and
organic contaminants, using methods like ASTM D5462 for dissolved metals analysis.
 Electrode Materials Testing:
 Corrosion Resistance: Assess electrode materials for corrosion resistance in a seawater
environment using ASTM G31 for corrosion testing.
 Membrane Materials Testing:

36
Ensure membrane materials meet required composition standards, such as ASTM D792 for density
or ASTM D570 for water absorption.
3.3 Material and Energy Flow Information

Overall reactions:
Anode: H2O(l) → 2H+(aq.) + 2e- + O2 (g)
Cathode: 2H+(aq.) + 2e- → H2 (g)
Overall: H2O(l) → O2 (g) + H2 (g)
Flow sheet
Assumptions
 The process is operating at steady state

 Heating and cooling occur isobarically
 Pressurisation and depressurisation of liquids occurs isothermally
 Seawater is used for any cooling and therefore relevant heat exchangers and pipelines are
constructed using corrosion resistant materials

37
 Seawater feed to each process is pH neutral and 26C, based on the process plants being located
offshore in the West Coast of Gujrat
 No heat or pressure is lost in pipelines
 Efficiency of RO, PEM and condenser is 40%, 80% and 100% resp.
As shown previously during electrolysis, one mole of water reacts to produce one mole of H2 and 0.5
moles of O2. Therefore, assuming 80 % conversion and knowing that the molecular weights of water,
hydrogen and oxygen are 18.02 g/mol, 2.02 g/mol and 31.99 g/mol respectively:
18.02 𝑔 𝐻2𝑂 → 2.02 𝑔 𝐻2 + 15.995 𝑔 𝑂2
Based on this, the theoretical mass of reactants for 1 kg production of Hydrogen:
8.899 𝑘𝑔 𝐻2𝑂 → 1 𝑘𝑔 𝐻2 + 7.935 𝑘𝑔 𝑂2
Production: 4.75 TPH green Hydrogen
Material balance across centrifugal pump
Streams Flowrate (TPH) Temperature(C) Pressure(psi)
S1 106.1031 26 14.7
S2 106.1031 26 60
Material balance across RO unit

38
Inlet Flowrate = 106.1031
Recovery = 40%
Outlet flowrate = 106.1031 * 0.4 = 42.44125
Stream Flow rate Pressure Temperature
S2 106.1031 60 26
S4 42.44125 60 26
S3 63.661875 60 26
Material balance across Mixer

39
Stream Flow rate Pressure Temperature
S4 42.44125 60 26
S9 10.37514 60 80
S5 52.8371 60 36.62
S10 0.010355 60 80
S13 0.010355 60 80
Energy balance for mixer
Heat lost by S9 + S10 + S13 = heat gained by S4

Let final temp be ‘x’
∴ mmixcΔTmix= ms4c ΔTs4
10.39585 * c * (80-x) = 42.44125 * c * (x- 26)
10.39585 * 80 + 42.44125 * 26 = (42.44125 + 10.39585) x
∴ x = 36.624°C

40
Material balance across Heat Exchanger
Stream Flowrate Pressure Temp
S5 52.8371 60 36.62
S6 52.8371 60 80
Material balance across PEME
S9
Stream Component Flowrate Pressure Temperature
S6 H2O 52.8371 60 80
S8 H2 4.95 60 100
S8 H2O 0.010355 60 100
S7 O2 37.69125 60 100
S7 H2O 0.010355 60 100

41
S9 H2O 10.37514 60 80
8.935Kg H2O gives 1Kg H2 from PEME
Using 80% conversion 52.8371 * 0.8 * TPH H2

.
Flowrate of O2 = 52.8371 – 10.39585 – 4.95 = 37.49125 TPH O2
Material balance across gas-liquid separator (Demister 1)
S8 H2O 0.010355 60 100
S8 H2 4.95 60 100
S10 H2O 0.010355 60 80
S11 H2 4.95 60 100
Material balance across gas-liquid separator (Demister 2)

42
S7 H2O 0.010355 60 100
S7 O2 37.69125 60 100
S13 H2O 0.010355 60 80
S12 O2 37.69125 60 100
Energy Balance:
The energy of each stream, Q, was calculated using Equation
𝑄 = 𝑚𝐶𝑝(𝑇−𝑇𝑟𝑒𝑓)
Assumption: Reference temperature = 0°C
Tempera Pressur Mass Flow Capacity Molar No of

Stream ture e rate Factor Mass Moles Density Cp Flow Enthalpy
tonnes per gram kg per
Celcius bar hour per mole x10^6 m3 cal/kgC MCal/hr
106.10312 5.894618
S1 26 1 5 0.9 18 056 1023.6 1000 2482.813125
106.10312 5.894618
S2 26 4 5 0.9 18 056 1032.5 1000 2482.813125
3.536770
S3 26 4 63.661875 0.9 18 833 1044.3 1000 1489.687875

43
2.357847
S4 26 4 42.44125 0.9 18 222 997.04 1000 993.12525
2.935394
S5 36.62 4 52.8371 0.9 18 444 997.04 1000 1741.405142
2.935394
S6 80 4 52.8371 0.9 18 444 971.6 1000 3804.2712
1.177958
S7 100 4 37.69467 0.9 32 438 4.128 7030 23849.41771
2.380177
S8 100 4 4.760355 0.9 2 5 0.25 3400 1456.66863
0.576396
S9 100 4 10.37514 0.9 18 6667 971.6 1000 933.7626
0.000575
S10 80 4 0.010355 0.9 18 2777778 971.6 1000 0.74556
S11 100 4 4.75 0.9 2 2.375 0.25 3400 1453.5
1.177851
S12 100 4 37.69125 0.9 32 563 4.128 7030 23847.25388
0.000575
S13 80 4 0.010355 0.9 18 2777778 971.6 1000 0.74556
3.4 Detailed Design of Equipment

3.4.1 Process Design
Pump Design
Suction pressure, P1 = 14.7 psi = 1.01 bar
Discharge pressure, P2 = 60 psi = 4.13 bar
Inlet fluid temperature = 299 K
Outlet fluid temperature = 299 K
Efficiency of pump, η = 80%
Inlet fluid density = 1023.6 kg/m 3
Outlet fluid density = 1023.6 kg/m 3
Average fluid density = 1023.6 kg/m 3
Mass flowrate of fluid = 106.103125* 103 kg/h
Volumetric flowrate of fluid = 103.6545 m3/hr = 0.02879 m3/s

44
Head loss in Pump = = 31.07m
. ×
Power intake = ×𝜐 = 11228.1 W = 11.2 kW
Heat Exchanger Design
Design for number of tubes, bundle diameter, shell diameter, tube side heat transfer coefficient
(HTC), shell side HTC, Overall HTC and pressure drop for shell side and tube side (using Kern ‘s
Method).
Mass flow rate of hot fluid (steam) = 30853.15 kg/h = 8.570 kg/s
Mass flow rate of cold fluid (water) = 52.8371*103 kg/h = 14.67655 kg/s
Heat loss by steam = Heat gained by water
𝑚 𝐶 Δ𝑇 = 𝑚 𝐶 Δ𝑇
8.570 × 6.212 × (320 − 𝑥) = 14.67655 × 4.18 × (80 − 36.62) = 270
Properties of hot fluid (steam)

Property Value Unit
Inlet temperature 320 °C
Outlet temperature 270 °C
Mass flowrate 8.570 kg/s
Viscosity 2*10-5 pa.s
Specific heat 6.212 kJ/kg.K
Density 20 kg/m3
Thermal conductivity 0.128 W/mK
Properties of cold fluid (water)

Property Value Unit
Inlet temperature 309.77 K
Outlet temperature 353.15 K
Mass flowrate 14.67655 kg/s

45
Viscosity 7.19*10-4 pa.s
Specific heat 4.18 kJ/kg.K
Density 994.03 kg/m3
Thermal conductivity 0.621 W/mK
Assumed U = 1800 W/m2°C [Fig 12.1 Coulson Richardson's Chemical Engineering Vol.6]
Exchanger Type and Dimensions and even the number of tube passes is usually the preferred
arrangement, as this positions the inlet and outlet nozzles at the same end of the exchanger, which
simplifies the pipework.
Start with one shell pass and 2 tube passes.
(320 − 270) − (80 − 36.62)

∆𝑇 = = 46.01
320 − 270
ln( )
80 − 36.62
(320 − 80)
𝑅= = 5.53
(80 − 36.62)
(270 − 36.62)
𝑆= = 0.823
(320 − 36.62)
𝐹 = 0.88
∆𝑇 = ∆𝑇 × 𝐹 = 46.01 × 0.88 = 40.48
Heat-Transfer Area
2808 × 10
𝐴 = = 38.53
1800 × 40.48
Layout and Tube Size
Use a split-ring floating head exchanger for efficiency and ease of cleaning. Neither fluid is
corrosive, and the operating pressure is not high, so a plain carbon steel can be used for the shell and
tubes.
Use 19.05 mm (3/4 inch) outside diameter, 14.83 mm inside diameter, 5 m long tubes (a popular
size) on a triangular 23.81 mm pitch (pitch/dia. = 1.25).

46
The flowrate of water is more than the flowrate of steam, so put the water through the tubes and
steam in the shell.
Number of Tubes
Area of one tube (neglecting thickness of tube sheets) = 𝜋 × 𝑑 × 𝐿 = 0.2992𝑚
.
Number of tubes = = 128.8 = 130
.
So, for 2 passes, tubes per pass = 65.
Check the tube-side velocity at this stage to see if it looks reasonable.
Tube cross-sectional area = 𝑑 = 0.0001727𝑚
So area per pass = 65 × 0.0001727 = 0.011𝑚
Volumetric flow = 14.67655 × = 0.01476 𝑚 𝑠
.
Tube-side velocity, 𝑢 = = 1.34 𝑚⁄𝑠
.
The velocity is satisfactory, between 1 to 2 m/s, but may be a little low. This will show up when the
pressure drop is calculated.
Bundle and Shell Diameter:
for 2 tube passes, K1 = 0.249, n1 = 2.207, so
130 .
𝐷 = 19.05 = 324.57
0.249
For a split-ring floating-head exchanger the typical shell clearance from Figure 19.10 is 54 mm, so
the shell inside diameter is 379.57 mm
𝐷 = 324.57 + 54 = 378.57
Tube-Side Heat-Transfer Coefficient
994.033 × 1.4 × 14.83 × 10

𝑅𝑒 = = 20605.144
1.0016 × 10
4.18 × 1.0016
𝑃𝑟 = = 6.74
0.621

47
𝐿
= 337
𝑑
𝑗 = 2.3 × 10
.
𝑁𝑢 = 2.3 × 10 × 20605.144 × 6.74 = 88.95
0.613
ℎ = 88.95 = 3676.75
14.83 × 10
Shell-Side Heat-Transfer Coefficient
Kern’s method will be used,
The baffle spacing = Ds/5, say 76 mm. This spacing should give good heat-transfer
without too high a pressure drop.
(23.81 − 19.05)
𝐴 = 378.57 × 76 = 0.005751𝑚
23.81
1.1
𝑑 = ((23.81) − 0.917(19.05) ) = 13.52𝑚𝑚
19.05
Volumetric flowrate on shell-side = 0.006158 𝑚 𝑠
Shell-side velocity = 1.07 𝑚⁄𝑠
200 × 1.07 × 14.83 × 10

𝑅𝑒 = = 15868.1
2 × 10
6.212 × 10 × 2 × 10
𝑃𝑟 = = 9.7
0.128
Use segmental baffles with a 25% cut. This should give a reasonable heat-transfer coefficient without
too large a pressure drop.
From Figure 19.29, jh = 4.5 × 10-3
Neglecting the viscosity correction
.
4.5 × 10 × 0.6 × 15868.1 × 9.7
ℎ = = 6700 𝑊 𝑚 ℃
13.52
19.05
1 1 19.05 19.05 × 10 × ln 14.83 1
= + 0.00017 + + + 0.0002
𝑈 3676.75 14.83 2 × 55 6700

48
𝑈 = 1914.7 𝑊 𝑚 ℃
5000 994 × 1.4

∆𝑃 = 2 8 × 4 × 10 × + 2.5 = 0.26𝑏𝑎𝑟
14.83 2
1914.7 − 1800
%𝑒𝑟𝑟𝑜𝑟 = × 100 = 6.372%
1800
The general range for acceptable design is an error with 30%, Therefore the design is acceptable.
Mixer Design:
Mixer Tank 1 Process Design
The information provided here relates to the mixing of Water (from RO unit) at rate of 42441.25 kg
per hour, recycle streams of Water (from PEM Elect, demister 1 and demister 2) at rates of 10375.14
kg per hour, 10375.14 kg per hour and 10375.14 kg per hour respectively.
Density of Water (at 25 degrees centigrade and 4 bar) - 997.04 kg/ m 3
Density of Water (at 80 degrees centigrade and 4 bar) - 971.60kg/m 3
Density of Water (at 100 degrees centigrade and 4 bar) - 958.5 kg/m 3

49
This procedure requires 120 minutes of residence time.
Water (from RO unit) has a volume of 42.567 m 3, and Water (from PEM elctrolyzer) has a volume of
10.824 m3and water (from demister1 and demister2) has a volume of 0.01068 m 3. The process's
intended volume (Design volume) is 57 m 3, because the combined volume of both streams is
56.4122 m3.
The given data involves equations related to D/H relates the aspect ratio of a vessel, where D
represents the diameter of a cylinder and H represents its height. The first equation shows that DIH is
equal to the ratio of twice the value of C1 to the sum of C2, C3, C4, and C5.
Here C1, C2, C3, C4, and C5, represent the concentrations of five different components in the vessel,
D/H = (2C1)/ (C2+C3 +C4+C5)
The second equation involves the values of C1, C2, C4, and C5, where C1 is equal to 2 times C2 and
C4 + C5 are equal to 0.2 times C2.
C1 = 2C2; C4+C5=0.2C2
This Simplifies to D being equal to 1.25H. The final equation involves the volume of the cylinder,
which is given as 2
D=2H(2C2)/ (C2 + 2C2, +0.2C2,)
D= 1.25H
V= (π*D* H)/4= 57 m3
Using the formula for the volume of a cylinder, which involves the values of D and H, we can solve
for D and H, which turn out to be D = 9.524 m and7.62 m, respectively.
So, D = 9.524 m and H = 7.62 m.
Agitator design: For proper mixing:
Da / Dt = 1/3 which shows that the ratio of the diameter of the agitator, Da to the diameter of the tank,
Dt
j / Di = 1/12 where j represents the clearance between the agitator blade and the tank wall, and Di
represents the diameter of the impeller.
E / Dt = 1/3 which relates the height of the impeller from the bottom of the tank, E, to the diameter of
the tank, Dt

50
W / Da = 1/5 which shows the ratio of the width of the agitator blade, W, to the diameter of the
agitator, Da
L / Da = 1/4 which shows the ratio of the length of the agitator blade, L, to the diameter of the
agitator Da
Using these equations, we can determine the values of different parameters. For example, given D t =
9.524, we can solve for Da, which turns out to be 3.174 m. Similarly, we can solve for the values J, E,
W, and L which are:
So, Da = 3.174 m; J = 0.1458m; E = 3.174 m; W =0.6348m; L = 0.7935m
Assuming that n = 100 rpm = 1.67 rps we are given the density, which is 975.75 kg/m 3 and the
viscosity, which is 0.705 x 10-3 Ns/m2
n = 100 rpm = 1.67 rps; density = 975.75 kg/m 3; µ = 0.705 x 10.3 Ns/m²
Agitator Power Consumption
The power requirements for agitation will depend on the degree of agitation required and
will range from about 0.2 kW/m³ for moderate mixing to 2 kW/m³ for intense mixing. The
shaft power required to drive an agitator can be estimated using the following generalized
dimensionless equation, the derivation of which is given in Coulson et al. (1999).
𝑁 = 𝐾 𝑅𝑒 𝐹𝑟
Where,
𝑃
𝑁 = 𝑃𝑜𝑤𝑒𝑟 𝑁𝑢𝑚𝑏𝑒𝑟 =
𝑑 𝑁 𝜌
𝑑 𝑁𝜌
𝑅𝑒 =
𝜇
𝑑 𝑁 𝜌
𝐹𝑟 = 𝐹𝑟𝑜𝑢𝑑𝑒 𝑁𝑢𝑚𝑏𝑒𝑟 =
𝑔
𝑃 = 𝑆ℎ𝑎𝑓𝑡 𝑃𝑜𝑤𝑒𝑟 , 𝑊
K = a constant, dependent on the agitator type, size, and the agitator-tank geometry
𝜌 = fluid density, kg/m³
µ = fluid viscosity, Ns/m²

51
N = agitator speed, s-¹ (revolutions per second) (rps)
Da = agitator diameter, m
g = gravitational acceleration, 9.81 m/s²
Values for the constant K and the indices b and c for various types of agitator, agitator-tank
geometries, and dimensions can be found in the literature (Rushton, Costich, and Everett (1950)). A
useful review of the published correlations for agitator power consumption and heat transfer in
agitated vessels is given by Wilkinson and Edwards (1972); they include correlations for non-
Newtonian fluids.
Typical power curves for propeller and turbine agitators are given below. In the laminar flow region,
the index "b" = 1, and at high Reynolds number the power number is independent of the Froude
number; index "c" = 0.

52
Using these values, we can calculate the Reynolds number, NRe which is a dimensionless number used
to predict the onset of turbulence in a fluid flow.
NRe = Da2 * np/µ = 2.3 * 105
where Da the diameter of the agitator, and np is the rotational speed of the impeller.
From NRe Vs Np graph:
The value of Np which represents the power number of the impeller, is given as 0.75.
The rotational speed of the impeller is assumed to be 100 revolutions per minute, which is equivalent
to 1.67 radians per second.
The diameter of the agitator is assumed to be 3.174 meters.

53
The density of the fluid being agitated is taken as 975.75 kilograms per cubic meter, and the dynamic
viscosity is given as 0.705 x 10-3 newton-seconds per square meter.
The Reynolds number, NRe is calculated using the diameter of the agitator, rotational speed, and fluid
properties. The calculated value of NRe is very high, which indicates turbulent flow conditions.
The power consumption of the agitator is calculated using the power number, rotational speed,
diameter of the agitator, and density of the fluid. The calculated value of power consumption, P, is
2301.73 watts.
P = Np * n3 * Da5 * ρ = 0.75 * (1.67)3* (3.174)5 * 975.75 = 1.09 MW
The torque, Tq required to rotate the agitator is calculated using the power consumption and rotational
speed. The calculated value of torque is 219.36 newton-meters.
Tq =P/(2π* n)= 1.038 * 105 Nm
The diameter of the inlet pipe for the incoming feed is calculated using the flow rate and density of the
feed.,
Diameter required for incoming feed,
Dc = 8.4 * w0.45/ ρ0.31
W = 10943 + 44675 = 55618
gives Dc = 8.4 * 3689.2650.45 / 868.360.31 = 135.809mm or 13.5809 inch
From Standard Pipe size:
Inner Diameter: 15.5 inches
Outer Diameter: 16 inches

54
PEM Electrolyser Design:
The minimum required energy for water splitting can be calculated from Gibbs free (ΔG) energy.
Standard conditions, Gibbs freeenergy for the splitting of water into hydrogen and oxygen can be
calculated by following equation,
∆𝐺 = 𝑛𝐹𝐸
Where,
 n = no. of electrons involved

 F = 96500 (Faraday’s constant)
 Erev = Reversible voltage
The reversible voltage can be calculated by the following Eqn
∆𝐺
𝐸 =
𝑛𝐹
However, at the time of water splitting some entropy is generated. Thus, it is more suitable to employ
enthalpy (ΔH) in its place of ΔG for the potential calculation.
The standard conditions, the change of enthalpy is ΔH = 285.84 kJ mol −1 and change of Gibbs free
enthalpy is ΔG = 237.22 kJ mol−1.
Therefore, the minimum required voltage (VTN) for the water electrolysis can be calculated by
following Eq.
Δ𝐻 Δ𝐺 𝑇Δ𝑆
𝑉 = = + = 1.48𝑉
𝑛𝐹 𝑛𝐹 𝑛𝐹
Where
 VTN = thermo-neutral voltage

 ΔS = change in entropy
 T = temperature
Typically, water electrolysis efficiency is calculated by the higher heating value (HHV) of hydrogen.
Since the electrolysis process water is supplied to the cell in liquid phase, efficiency can be calculated
by the following Eq.

55
𝑉
𝜂=
𝑉
Where
 VTN = Thermo-neutral voltage

 Vcell = Cell voltage
Therefore, the water electrolyser efficiency can be calculated by any current density. Since operating
the lower current densities at lower voltages, the electrolyser efficiency becomes higher
Considering the terminal cell voltage of PEM electrolysers to be 1.8 V under the typical operational
current density of 1.2 A/cm2
We have the equation:
18.02 𝑔 𝐻2𝑂 → 2.02 𝑔 𝐻2 + 15.995 𝑔 𝑂2
1
Anode: O( ) → O ( ) + 2e
2
Cathode: H O( ) + 2e → H ( ) + O( )
Overall: H O( ) → O ( ) +H ( )
From the equation we can see that it would take 2 moles of electrons to make 1 mole of hydrogen
gas.
Charge for 1 mole of hydrogen gas=2×Faraday’s constant
= 2 ×96485 C/mol
= 192970 C/mol
Hydrogen production rate (mol/s) = 4750 kg/hr × 1000 g/kg /(2.016 g/mol × 3600 s/hr)
= 654.486 mol/s
Charge for desired hydrogen production rate = 654.486 mol/s× 192970 C/mol
= 12,62,96,227.4 C/s
Current requirement = 12,62,96,227.4 A
Power requirement of PEM electrolyser P=𝐼 cell x 𝑉𝑐𝑒𝑙𝑙

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= 12,62,96,227.4x 1.8
= 227333.209048 kW
Membrane surface area requirement 12,62,96,227.4/ 1.2
= 105246856 cm2
= 10524.68562 m2
Now, from the following graph we have,
Fig. Dependence of electrolysis-cell area on current density.
Area of a cell from above curve = 0.93 m2
No. of cells = 133.54
Based on the calculation of the approach, the hydrogen electrolyser designed in this study is as
follows:
Type Proton Exchange
Operating Temperature 80° C
Number of units 10 units
Configuration Parallel
Number of cells 134 per unit

57
Membrane type Nafion 115
Process Design of RO unit
TDS value of seawater from Arabian Sea – 35000 ppm.
TDS value of seawater: 35000ppm

We are using single stage RO unit which has recovery around 40%
Flux range of seawater: -11-17 L/m2h
: 15 L/m2h
Concentration of concentrate = × [1 − (1 − 𝑆) ]
𝐶𝐹
= × [1 − (1 − 0.4) . ]
0.4
𝐶𝐹
= × [1 − (1 − 0.4) . ]
0.4
35000
= × [1 − (1 − 0.4) . ]
0.4
= 445𝑝𝑝𝑚
Power Requirement
Specific energy: 4.28 kWh/m3
Power = 4.28 kWh per 997 kg
.
= × 106.103125 × 1000
= 455.487 units per hour (1unit = 1kWh )

58
Reverse Osmosis (RO) Process Design :
Module Requirements:
•Qp/Qfi = 0.40 (Recovery rate)
•Salt rejection, R′ = 0.99
•Salt concentration in the feed, Cfi = 3.5%
•Retentate concentration, Cfo
•Exit concentration of the mixed permeate water, Cp = 0.025%
•Osmotic pressure of 5% brine = 39.5 atm
Step 1: Salt Balance and Concentration:
1.Retentate Concentration, Cfo:
Cfo=Cfi×(1−θwo)-R′
Cfo = Cfi (1- ϴwo)-R′ = 3.5 x (1-0.40)-0.99 = 8.670%
2.Osmotic Pressure Calculation:
Assume osmotic pressure of 5% brine (linear in salt concentration) is 39.5 atm.
Osmotic pressure of the feed brine (3.5%) = (39.5/5) x (3.5) = 27.65 atm
Osmotic pressure of the exit brine (8.670%) = (39.5/5) x (5.186) = 68.493 atm
3.Average Osmotic Pressure, Δπ:
Take the average osmotic pressure, ∆π value to calculate the effective pressure driving force (neglect
the osmotic pressure of permeate)
(∆π)av = (27.65 + 68.493)/2 = 48.07 atm
4.Effective Pressure Driving Force:
(∆P - ∆π)av = (50 -48.07) = 1.93 atm
5.Water Flux Calculation:

59
water permeation coefficient =0.0017917 m³/m2.hr.atm
water flux = water permeation coefficient x (∆P - ∆π)av
Water flux = (0.0017917) x (1.93) = 3.457 m³/m2.hr
Step 2: Total Membrane Area Required
QP represents the flow rate of the permeate
Production of potable water is 3351.3 kg/hr from S4 and and density is 0.99396 gm/cc
Total membrane area required = production of 3.375 m³/hr potable water/water flux
=3.375/0.003457 = 976.280 m2
Assume Effective Membrane Area: spiral wound module (Type) of 5 m2 effective membrane area each
is used
Number of modules = 976.280/5 = 195.256 ≈ 196
Step 3: Power Recovery
1.Total Feed Water Requirement:
Qfi=Qfo+QP= 3.375 m³/hr
Where,
Qfo represents the flow rate of the feed water leaving the RO modules
Qfi represents the flow rate of the feed water entering the RO
2.Salt Balance Equations:
(Qfo+3.375) × (0.035) =(Qfo×0.08670) +(3.375×0.00025)
0.035×Qfo+0.118125 = 0.08670×Qfo+0.00084375
0.035×Qfo−0.08670×Qfo = 0.00084375−0.118125
Qfo× (0.035−0.08670) =−0.11728125

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Qfo ≈ 0.0517/0.11728125 ≈ 2.265 m³/hr
3.Power Efficiency:
Power efficiency (efficiency, η = 0.7) = (Qfo x ∆P) x η
Qfo=2.265 m³/hr = 36002.265 m³/s
ΔP=50 atm=50×1.01325×10^5 Pa (1 atm = 1.01325 x 10^5 Pa)
Qfo=36002.265=6.291×10−4 m³/s
ΔP=50×1.01325×10^5=5.06625×10^6 Pa
Power efficiency(η)=6.291×10^-4 m³/s×5.06625×106 Pa×0.7
Power efficiency(η)=2.215 kW
3.4.2 Mechanical Design

1. Demister Unit-02
From steam tables, at 4 bar: saturation temperature 152.903 °C, liquid density 914.23 kg/m3 , vapor
density 2.7400 kg/m3 .
ut = 0:07((914.23− 2.7400)/2.7400)^1/2 = 1.276 m/s
Vapor volumetric flow rate = 37694.67/(3600×2.7400)= 3.8213 m3/s
Minimum allowable diameter:
Dv = ((4 × 3.8213 /(π × 1.276))^0.5 = 1.9525 m, round to nearest standard vessel size, 2 m
Liquid volumetric flow rate = 10375.14/(3600 × 914.23) = 3.16 × 10^−3 m3 /s
Allow a minimum of 10 minutes hold-up.
Volume held in vessel = 3.16 × 10^−3 ×10 × 60 = 1.8943 m3
Liquid depth required, hL = volume held up vessel/cross-sectional area = 1.8943/(π×(2^2)/4)= 0.598m

Increase to 0.3 m to allow space for positioning the level controller.
Similarly doing for Demister-01 with respective streams:

61
Component Inlet Vapour Inlet water Min allowable Liquid depth required
(hL)
stream(kg/h) Stream(kg/h) diameter (Dv)
Demister 1 4750 10.37514 1

2.711
Demister 2 37694.67 10.37514 2 0.898
III. Mechanical Design of Heater
Heat Exchanger is assumed to be a cylindrical vessel under Internal Pressure.
Shell Thickness Calculations
Operating Pressure = 1 bar
Design Pressure (PD) = 1.05 *1 = 1.05 bar
Shell inside Diameter (Di) = 14.83mm (From Process Design)
Material of Construction = IS: 2002-1962 Grade 1
f = 110 MN/m2 (From IS: 2002-1962)
Length of vessel (L) = 2*D + L = 5.029 m
Weld joint efficiency factor, J = 0.85
𝑡 = 𝑃𝐷*𝐷𝑖 / (2𝑓𝐽−𝑃𝐷) = 0.0837mm
Corrosive Allowance = 3 mm
Thus, thickness (t) = t + CA = 3.0837 mm
After rounding off, thickness = 5 mm
Do = Di + 2*t/1000 = 14.84m
t/Di = 0.3371 < 0.25
Hence, assumption is valid; the vessel can be taken as membrane under internal pressure.

62
Head design
For the cylindrical design of exchanger, we have chosen Torispherical head Material of
construction is same as that of shell
Assuming, Ri = Do = 19.05mm
Sf = 40 mm
ri = 0.06*Ri =0.0031mm
Assuming, Ri = Ro = Do = 19.05 mm
ri = ro = 0.0031 mm
𝑡 = 𝑝𝐷𝑜𝐶 /2𝑓𝑗 Ref: Equation 4.2.20, Page 52, BC Bhattacharya
Since C is a function of t, we need to do the iterations.
hE is effective external height of head without straight flange and equal to least of the below
Three: 0.07827
ℎ𝑜 = 𝑅𝑜 − √(𝑅𝑜 − 𝐷𝑜/2 )(𝑅𝑜 + 𝐷𝑜/2 − 2𝑟𝑜) = 0.10773 m
𝐷𝑜 ^2 /4𝑅𝑜 = 0.0465 m
√ 𝐷𝑜*𝑟𝑜/ 2 = 0.0322 m
Out of these three values calculated, the least value is taken as effective height (hE)
Taking J = 0.85,
Using table 4.1 (A), Page 53, BC Bhattacharya
Where hE / Do = 0.17311
t/Do = 0.00533
t = 0.0009934 m
tf = 1.06*(0.005+.003) = 0.008 m == 8 mm
After rounding off thickness of 8 mm is selected for the head.
Nozzles and branch pipes

63
Shell Nozzle
Material of construction: Same as that of the shell
f = 110 MN/m2
ts =5 mm
tr = 0.26921 mm
corrosion allowance = 0.003 m
dnozzle = 0.25 m
Do = 0.186 m
Design Pressure PD = 1.05 bar
Area to be compensated (A) = (d+2c) * tr = 0.0000689 m2
Area available from shell (As) = (d + 2c) * (ts − tr − C) = 0.002491 m2
Area available from nozzle for reinforcement
An = Ao (no inside protrusion) = 2H1* (tn-tr`-c)
tr` = 𝑝𝑑𝑜/2𝑓𝐽+𝑝 = 1.136 mm
tn = 0.016 m
d (inside diameter of nozzle) =0.25 m
H1 = √(𝑑 + 2𝑐)(𝑡𝑛 − 𝑐) = 0.05769 m
An = 0.0014837 m2
An + As = 0.00269 m2
A is less than sum of As and An.
No ring pad is required
Design Pressure = 0.105 MPa
Taking ―Asbestos filled corrugated metal jacket of stainless steel (Table7.1Page 103,BCB)
y = 45 MN/m2

64
m = 3.5
Minimum actual gasket width = 10 mm.
𝑑𝑜 /𝑑𝑖 = ( (𝑦−𝑝𝑚)/ (𝑦−𝑝(𝑚+1) )^ 0.5 = 1.0011783524
di =B+0.01 = 0.196 (where B= shell outside diameter)
do = 0.1962308 m
Gasket width = (do− di) / 2 =0.11677114 mm, less than 10 mm
Gasket width, N = 0.115444 mm
Basic Gasket seating width, bo = N/2 =0.057722 mm
Diameter at location of gasket load reaction, G = di + N =0.311444 m
Estimation of bolt loads
Bolting Material – 5 % Cr Mo steel
Allowable stress of bolting material = 138 MN/m2
Load due to design Pressure:
H = 3.14*G^2*P/4 =0.0018097 MN
Load to keep joint tight under operation:
Hp = πG(2b) mp =1.491849* 10^-5 MN
Total operating load
Wo = H + Hp =0.0018246 MN
Load to seat gasket under bolting-up conditions,
Wg = πGby = 0.0009133 MN
Wo is greater than Wg and therefore, Controlling load =0.0018246 MN
Minimum Bolting Area
S0 = 138 MN/m2
Where Sg = 138 MPa (Table 7.5 page 108 BCB)

65
Am = A0= Wo / S0 =0.0000132219 m2
C2 = ID + 2(g1 + R) =3.1826
g1 =1.415 *g0 = 7.075 (g0 = shell thickness)
R = Radial clearance from bolt circle to point of connection of hub or nozzle and back of flange
Bolt Specifications for Heat Exchanger
Bolt Size 12 mm
Bolt Thickness 1.5 mm
R 20 mm
C1 111.3 mm
C1 – C2 (since it is negative, no flange required) -140.85 mm
Since C1 – C2 is negative for minimum bolt size, therefore flange is not required
IV Mechanical Design of RO
Number of elements required
𝑄𝑃
𝑁 = (𝑖𝑛 𝐿𝑃𝐻)
𝑓𝐴
111.6875 × 1000
=
0.997 × 15 × 37.2
Active area is 37.2 m2 for SW30ULE-yooi element type
= 200 elements required
Number of pressure vessel
For large scale plant we generally use 6-element vessel
200
𝑁 = = 34𝑃𝑉 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑
6
Staging ratio will be one cause we are using single stage

66
3.4.3 Mechanical Drawing
Heat Exchanger

67
Centrifugal Pump
3.4.4 Specifications of process equipment
Heat Exchanger
Type of Reactor Shell and tube
Material Used Cupro-Nickel
Overall Heat Transfer Coefficient 1914.7 W/m2 °C

68
Length 5m
Number of tubes 130
Pitch 1.25-inch triangular pitch
Shell inner diameter (mm) 379.57 mm
Cooler 1
Length 2.35 m
Number of tubes 100
Cooler 2
Length 2.35 m

69
Number of tubes 170
Demister 1
Material Used Carbon Steel
Pressure 4 Bar
Temperature 100 °C
Diameter 1m
Liquid Length 0.3 m
Demister 2
Material Used Carbon Steel
Pressure 4 Bar
Temperature 100 °C
Diameter 2m
Liquid Length 0.69 m
PEM Electrolyser

70
Temperature 80℃
Membrane Surface Area 1242 m2
Number of units 134
Configuration Parallel
Membrane Type Nafion 117
RO Unit
Membrane Surface Area 976.28 m2
Number of modules 196
Feed water temperature 25
Feed water pressure 1 atm
Membrane type Tubular
3.4.5 Engineering problems and their possible remedies
Problems in Heat Exchangers
The most common heat exchanger problem for many chemical engineers is fouling which can occur
within the inside of a tube wall and decrease performance and even damage the heat exchanger in the
long run.
Fouling is a term used to describe material which builds up on the inside of a tube wall within heat
exchangers and in turn affects the performance of the heat exchanger.
Not treating fouling can lead to other major heat exchanger problems which can affect heat transfer
as well as the pressure drop within your heat exchanger.
Most common causes of fouling are:

71
• Settlement of sludge, rust, or dust particles
• Corrosion
Possible Remedies for fouling problem:
1. Choosing a material of construction which does not easily corrode or produce voluminous deposits
of corrosion products. If chemical removal of fouling is planned, the material selected must also be
resistant to attack by cleaning solutions.
2. Some types of fouling can be controlled and minimized by using high fluid velocities.
3. If fouling cannot be prevented from forming, it is necessary to make some provisions for its
periodic removal. Some deposits can be removed by purely chemical means. Since chemical
cleaning does not ordinarily require the removal of equipment. It is the most convenient of cleaning
techniques.
Major engineering problems related to PEM (Proton Exchange Membrane) electrolyzers and their
potential remedies:
Problems in PEM Electrolyzers:
1. Membrane Degradation: Over time, the proton exchange membrane in PEM electrolyzers can
degrade due to chemical and mechanical stresses, leading to decreased performance and efficiency.
2. Catalyst Poisoning: Contaminants in the feed water or electrolyte can poison the catalysts used in
PEM electrolyzers, reducing their activity and efficiency.
3. Gas Crossover: Cross-contamination of hydrogen and oxygen gases through the membrane can
occur, leading to decreased purity of the produced gases and potential safety hazards.
4. Water Management: Proper water management is crucial in PEM electrolyzers to maintain optimal
hydration levels within the membrane while preventing flooding or drying out, which can degrade
performance.
Remedies for PEM Electrolyzer Problems:
1. Advanced Membrane Materials: Utilizing advanced membrane materials with improved durability
and chemical resistance can mitigate membrane degradation, extending the lifespan of PEM
electrolyzers.

72
2. Catalyst Design and Protection: Develop catalysts with increased resistance to poisoning and
implement effective filtration or purification systems to remove contaminants from the feed water or
electrolyte.
3. Membrane Barrier Enhancement: Implementing improved membrane barrier designs or coatings

can help reduce gas crossover, enhancing gas purity and safety in PEM electrolyzers.
4. Integrated Water Management Systems: Incorporating sophisticated water management systems

that regulate water distribution within the electrolyzer can optimize membrane hydration levels and
prevent flooding or drying, ensuring stable operation.
Major engineering problems related to sea water desalination using Reverse Osmosis (RO)
technology and their potential remedies:
Problems in Sea Water Desalination using RO:
1. Membrane Fouling: Fouling of the RO membranes by organic matter, minerals, and other
contaminants present in seawater can decrease water permeability and salt rejection, leading to
reduced efficiency and increased operating costs.
2. Scaling: Scaling occurs when minerals such as calcium carbonate, calcium sulfate, and silica
precipitate on the membrane surface or within the RO system, reducing water flow rates and salt
rejection efficiency.
3. Energy Consumption: RO desalination typically requires significant energy input, primarily for
pressurizing the feed water to overcome osmotic pressure. High energy consumption can increase
operational costs and carbon footprint.
4. Corrosion and Material Compatibility: Seawater contains corrosive elements such as chloride ions,
which can degrade RO system components and materials over time, leading to equipment failure and
maintenance issues.
Remedies for Sea Water Desalination using RO:
1. Pre-treatment Systems: Implementing effective pre-treatment systems such as sedimentation,

coagulation, and filtration can remove suspended solids, organic matter, and bacteria from seawater,
reducing the risk of membrane fouling.

73
2. Antiscalant Chemicals: Adding antiscalant chemicals to the feed water can inhibit the precipitation
of scaling minerals, preventing membrane scaling and extending membrane lifespan.
3. Energy Recovery Devices: Installing energy recovery devices such as pressure exchangers or
energy recovery turbines can recover and reuse energy from the brine stream, reducing overall
energy consumption and operational costs.
4. Corrosion-resistant Materials: Using corrosion-resistant materials such as titanium or special

coatings for RO system components can mitigate corrosion effects and prolong equipment lifespan in
seawater environments.
3.5 Material Storage & Handling Facilities

3.5.1 H2 (Hydrogen)
Table: Type of hydrogen Hazars and description of necessary first aid measures
TYPES OF Most important symptoms/effects, Response and necessary First Aids

HAZARD/ acute and delayed
EXPOSURE
Fire FLAMMABLE GASES Do not extinguish, unless leak can be stopped

safely. In case of
leakage, eliminate all ignition sources.
Ingestion No known significant effects or keep drums, etc., cool by spraying with water.
critical hazards.
Inhalation No known significant effects or Remove victim to fresh air and keep at rest in a
critical hazards. position comfortable for breathing. If not breathing,
if breathing is irregular or if respiratory arrest
occurs, provide artificial respiration or oxygen by
trained personnel. It may be dangerous to the
person providing aid to give mouth-to-mouth
resuscitation. Get medical attention if adverse
health effects persist or are severe. If unconscious,

74
place in recovery position and get medical attention
immediately. Maintain an open airway. Loosen
tight clothing such as a collar, tie, belt or waistband.
Skin Contact with rapidly expanding gas Flush contaminated skin with plenty of water.
may cause burns or frostbite Remove contaminated clothing and shoes. To avoid
the risk of static discharges and gas ignition, soak
contaminated clothing thoroughly with water
before removing it. Get medical attention if
symptoms occur. Wash clothing before reuse.
Clean shoes thoroughly before reuse.
Eyes Contact with rapidly expanding gas Immediately flush eyes with plenty of water,
may cause burns or frostbite. occasionally lifting the upper and lower
eyelids.
Check for and remove any contact lenses
Continue to rinse for at least 10 minutes. Get
medical attention if irritation occurs.
Precautions for safe handling
Protective  Wear appropriate PPE.

measures  Avoid breathing the gas; use in well-ventilated areas or wear a respirator if
ventilation is inadequate.
 Do not enter enclosed areas unless well-ventilated.
 Do not puncture, incinerate, drag, roll, slide, or drop cylinders.
 Close the valve after each use and when the cylinder is empty.
 Protect cylinders from physical damage; use a hand truck for movement.
 Use non-sparking tools.
 Avoid contact with eyes, skin, and clothing.
 Empty containers may still contain hazardous residue.
 Store away from heat, sparks, open flames, or any ignition sources.

75
 Use explosion-proof electrical equipment for ventilation, lighting, and
material handling.
Advice on general  Eating, drinking, and smoking are not allowed in areas where this material
occupational is handled, stored, or processed.
hygiene  Workers must wash their hands and face before eating, drinking, or
smoking.
 Remove contaminated clothing and protective equipment before entering
areas designated for eating.
Conditions for safe  Store the material in accordance with local regulations.
storage, including  Store in a segregated and approved area.
any  Store away from direct sunlight in a dry, cool, and well-ventilated area.
incompatibilities  Keep away from materials that are incompatible (refer to Section 10).
 Eliminate all potential ignition sources.
 Store cylinders upright, with valve protection cap securely in place, and
ensure they are firmly secured to prevent tipping.
 Keep the container tightly closed and sealed until ready for use.
Spills and leaks

The steps to take in case of a hydrogen leak:
 Evacuation and Control: Immediately evacuate the area and secure entrances to prevent
access.
 Eliminate Ignition Sources: Ensure all potential ignition sources like flames or sparks are
eliminated.
 Ventilation: Use ventilation to disperse the leaked gas safely.
 Stop the Leak: If possible, stop the flow of gas. For cylinder leaks that can't be stopped in
place, move the cylinder to an open, safe area and repair or allow it to empty.
 Avoid Confined Spaces: Avoid hydrogen from confined spaces like sewers due to explosion
risks.
 Cool Containers: Use water spray to cool containers to prevent overheating.
 Air Monitoring: Conduct air monitoring to confirm oxygen levels are above 19.5%.

76
 Disposal: Hydrogen may need to be treated as hazardous waste. Contact your state's
Department of Environmental Protection (DEP) or the regional EPA office for guidance on
disposal.
Chronic Health Effects

The following chronic (long-term) health effects can occur at some time after exposure to Hydrogen
and can last for months or years:
Cancer Hazard
According to the information available to the New Jersey Department of Health and Senior Services,
Hydrogen has not been tested for its ability to cause animal cancer.
Reproductive Hazard
According to the information available to the New Jersey Department of Health and Senior Services,
Hydrogen has not been tested for its ability to affect reproduction.
Other Effects
No chronic (long-term) health effects are known at this time.
3.5.2 Seawater
The hazardous chemical handling protocols for seawater treatment processes:
 Safe Chemical Handling: Strict guidelines ensure chemicals used in seawater treatment are
handled, stored, and disposed of safely.
 Protective Equipment (PPE): Workers must use appropriate PPE like gloves, goggles, and
respirators to avoid exposure to chemicals and contaminants.
 Emergency Response Plans: Detailed plans outline steps to follow in case of chemical spills
or leaks to protect personnel and the environment.
 Training and Education: Regular training informs workers about safety procedures, hazards,
and emergency response.
 Air Quality Monitoring: Continuous monitoring detects harmful vapours or gases released
during operations that could endanger workers' health.
 Prevention of Waterborne Pathogens: Measures are taken to prevent the growth and spread
of bacteria, viruses, and algae that pose health risks.

77
 Health Surveillance: Workers exposed to seawater and chemicals undergo regular health
checks to detect and prevent adverse health effects.
 Environmental Impact Assessment: Assessments evaluate potential environmental impacts
and implement measures to minimise harm to surrounding ecosystems.
3.5.3 Oxygen
Oxygen, a colourless, odourless, and tasteless gas, is non-flammable but supports combustion
vigorously. Materials typically non-combustible in air can burn in an oxygen-enriched atmosphere
(>23%).
 Hazards: Shipped at pressures exceeding 2000 psig, pure oxygen at high pressure reacts
violently with common materials like oil, grease, and hydrocarbons. Inhalation of 100%
oxygen can induce nausea, dizziness, lung irritation, and severe conditions like pulmonary
Edema or pneumonia. Liquid oxygen, cryogenic in nature, can cause significant tissue damage
upon exposure.
 Storage & Handling: Regulated by safety codes, oxygen storage in the gaseous state is capped
at 1,500 cubic feet per control area, with allowances under specific conditions. Precautions
include keeping oil, grease, and combustible substances away from cylinders, valves, and
fittings. Cylinders should be stored in well-ventilated, well-lit areas, away from heat sources
and combustibles. They must also be protected from unauthorized access and physical damage,
stored upright, and secured to prevent tipping.
 Precautions When Handling: Avoid contact between oxygen and combustible materials, and
handle cylinders with clean hands or gloves free from oil. Use cylinder carts for safe
transportation, avoiding rolling.
 Disposal: Empty oxygen cylinders should be returned to the distributor promptly.
Proper storage, handling, and disposal of oxygen cylinders are crucial to mitigate fire, health, and
safety risks associated with this essential gas.

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3.6 Process Instrumentation & Control and Safety Aspects
For the plant described, where process control and instrumentation are critical for efficient and safe
operation, let's look at the key equipment and their role in the overall process:
1.Mixer:
 Purpose: The mixer is used to combine different feedstocks or reactants homogeneously before
they enter the reactor.
 Control and Instrumentation:
 Flow Control: Instruments measure and control the flow rates of various components
entering the mixer to ensure proper mixing ratios.
 Temperature Control: Monitoring and controlling the temperature of input streams to
maintain optimal conditions for mixing.
 Level Control: Ensuring proper levels of liquids in the mixer to prevent overflow or
inadequate mixing.
2. Electrolyser:
 Purpose: To separate hydrogen and oxygen from water using electrolysis.
 Temperature Control: Crucial for controlling reaction rates and preventing runaway
reactions; temperature sensors and controllers are used.
 Pressure Control: Maintaining optimal pressure inside the electrolyser to ensure safe
and efficient operation.
 Safety Interlocks: Automatic shutdown systems based on critical parameters like
temperature, pressure, and level to prevent accidents.
3. Separation System (e.g., condenser):

 Purpose: Separation of reaction products and unreacted feedstocks based on differences in boiling
points or other physical properties.
 Temperature Control: Monitoring and controlling temperatures at different stages to
facilitate separation of components.
 Pressure Control: Adjusting pressure conditions to optimize separation efficiency.

79
 Level Control: Ensuring proper liquid levels in distillation columns to prevent flooding
or dry runs.
 Composition Monitoring: Monitoring product compositions to ensure desired purity
levels.
 Reflux Control: Adjusting reflux ratios for optimal separation efficiency.
In summary, the control and instrumentation of key equipment such as mixers, electrolysers, and
separation systems (like condensers) in the plant are crucial for:
 Ensuring precise process control to meet production specifications and optimize product quality.
 Enhancing process and equipment safety by monitoring critical parameters and implementing
safety interlocks.
 Meeting environmental regulations by controlling emissions and effluents.
 Maximizing operational efficiency and cost competitiveness through optimized process control
strategies.
Each piece of equipment requires specific sensors, controllers, and automation systems tailored to its
function within the overall process. This integration of control and instrumentation plays a fundamental
role in the successful and sustainable operation of chemical plants.
Safety Aspects:
Safety is a primary requisite for every industry. To increase safety, hazards must be identified in the first
place. Alarms are used to alert operators of serious and potentially hazardous, deviations in process
conditions. Key instruments are fitted with switches and relays to operate audible and visual alarms on the
control panels. Where delay or lack of response by the operators is likely to lead to rapid developments of
a hazardous situation, the instrument would be fitted with a trip system to activate automatically to avert
the hazard, such as shutting drum pumps, and closing valves, operating emergency systems. Where it is
necessary to follow a fixed sequence of operations e.g., during plant start up or plant shut
down, or in batch operations, interlocks are included to prevent operators from departing from the required
sequence. They may be incorporated in control system design, as pneumatic or electric relays, or maybe
mechanical interlocks.

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4. Environmental Protection & Energy Conservation
4.1 Environmental Aspects
4.1.1 Air Pollution
The Central Pollution Control Board (CPCB) in India provides guidelines and standards for various
industries, including those related to green hydrogen production.
The primary contributor to potential air pollution is associated with electricity generation, however,
PEM electrolysers ensure generation without or with very low carbon emissions.
Necessary Treatment/Mitigative Measures:
 Advanced Emission Control Technologies; use of efficient membrane and catalysts that
minimize emissions
 Environmental Monitoring for PEM Electrolysis
 Life Cycle Assessment (LCA)
 Implementing effluent quality control measures
4.1.2 Liquid Effluents
Liquid effluents from seawater electrolysis for hydrogen production, particularly using Proton
Exchange Membrane (PEM) technology, can originate from multiple stages of the process, each
containing specific sources of concern. It is essential to understand the potential sources of liquid
effluents and their effluent standards to ensure effective management and compliance with
environmental regulations.
 Waste brine: This is the concentrated saline solution that remains after the desalination process,
and it contains high concentrations of salts and other impurities, posing environmental
challenges during disposal if not managed appropriately. Disposal of this waste brine can pose
environmental challenges, especially if not managed properly.
 Chemical additives and cleaning agents: Various chemicals such as antiscalants, coagulants,
and cleaning agents are often used in the pre-treatment and maintenance of the reverse osmosis
(RO) membranes. The residues of these chemicals can be present in the liquid effluents.
 Degraded membranes and components: The degradation of RO membranes and other
components within the system can lead to the release of degraded materials or by-products into

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the effluent stream. Electrolyte solutions used during the electrolysis process might undergo
changes, potentially leading to the presence of by-products or contaminants that require
suitable management in the effluent stream. The discharged water after the entire process might
still contain residual impurities and chemicals that were not entirely removed during the
purification process. Therefore, it is crucial to ensure that the discharge water complies with
environmental standards to mitigate potential adverse effects on the surrounding ecosystem.
 Electrolyte solutions: During the electrolysis process, the electrolyte solution may undergo
changes and could potentially contain by-products or contaminants that need to be properly
managed in the effluent stream.
 Discharge water: The discharged water after the entire process may contain residual impurities
and chemicals that were not completely removed during the purification process. It is crucial
to ensure that the discharge water meets environmental standards to minimize any potential
adverse effects on the surrounding ecosystem.
Efficient management and treatment of these liquid effluents are vital to minimize environmental
impact and ensure compliance with regulatory standards for water quality and environmental
protection. Adequate treatment methods such as advanced filtration, chemical treatments, and
appropriate disposal techniques should be implemented to ensure that effluents meet stringent
environmental standards. Regular monitoring and analysis of effluents are necessary to identify any
deviations from the established standards and promptly address any potential environmental risks.
4.1.3 Solids Disposal

Solid Wastes in PEM Electrolysis:
1. Quantity and Properties:

Solid waste generation in PEM electrolysis is relatively minimal compared to some other industrial
processes. However, potential sources of solid waste might include:
 Membrane Degradation Products: The proton exchange membrane used in the electrolysis
process is subject to degradation due to various factors such as high temperatures, exposure
to different ions, and mechanical stress during operation. As a result, these membranes can
undergo physical and chemical changes, leading to the formation of degraded membrane
products. These products might include fragments or particles of the membrane material
itself, which can vary in size, composition, and quantity based on the duration of use and
operating conditions.

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 Electrodes Degradation Products: The electrodes employed in the electrolysis process are
subjected to electrochemical reactions. Over time, these electrodes can degrade due to
processes like corrosion or chemical reactions, leading to the production of solid waste.
The waste generated from electrode degradation might comprise metallic particles, oxides,
or other electrode materials. The quantity and properties of this waste largely depend on
the electrode material used, the current density, and the operational time of the electrolysis
system.
The properties of the solid waste predominantly include:
 Non-hazardous Nature: The waste primarily comprises materials that are not considered
hazardous. However, caution must be exercised during handling and disposal to prevent
environmental impact.
 Polymeric and Metal Components: The ion exchange membranes are polymer-based,
typically PFSA materials, while the electrodes contain metals like platinum or other
catalysts.
2. Disposal Techniques:
Recycling and Reuse: The materials used in PEM electrolysis, such as the membranes and
electrode materials, might be recycled or reused to minimize solid waste generation. This method
aims to reduce the need for raw materials, limit waste, and decrease the environmental footprint of
the hydrogen production process.
Membrane Materials
 Material Reclamation:
 Grinding and Shredding: Degraded membranes can be mechanically processed through
grinding or shredding into smaller pieces or powders. This increases their surface area
and facilitates subsequent processing steps.
 Chemical Treatment: Chemical treatments such as dissolution or dissolution-
reprecipitation techniques can help break down degraded membranes into constituent
materials or recover specific components for reuse.
 Reconstitution or Reprocessing:
 Melting and Reforming: Some membrane materials, especially plastics or polymers,
can be melted and reformed into new shapes or sheets, ready for reuse in non-critical
applications.

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 Extrusion and Moulding: By using extrusion or moulding processes, degraded
membrane materials can be reshaped into different forms suitable for alternative
purposes.
 Reusability in Non-Critical Applications:
 Non-Critical Use: Materials recovered from degraded membranes might not retain the
original pristine properties needed for the electrolysis process but can still be
repurposed in non-critical applications. For instance, the recovered materials might find
use in non-demanding industrial or construction applications.
Electrode Materials:
 Metal Recovery and Recycling:

Utilize processes such as smelting or chemical leaching to recover metals from spent
electrodes. These recovered metals can be reused in various industries or within the hydrogen
production process, reducing the need for new raw materials.
Implement initiatives for electrode collection and recycling programs, encouraging
stakeholders to return used electrodes for recovery and recycling.
Utilizing Processes for Metal Recovery:
 Smelting: Smelting is a common method used for metal recovery from spent electrodes. It
involves heating the electrodes to high temperatures, causing the metals to melt and
separate from other materials. Once melted, the metals can be collected and refined for
reuse.
 Chemical Leaching: This method involves using chemical solutions to dissolve and
separate metals from the electrode materials. Through leaching, specific metals can be
extracted, purified, and then used for various purposes.
Applications of Recovered Metals:
 Reuse in Various Industries: The recovered metals from spent electrodes, such as platinum,
palladium, or other precious or non-precious metals, can be utilized in various industries.
These metals often have high value and can serve as raw materials to produce new products
or as components in manufacturing.
 Integration within Hydrogen Production: Recovered metals might be reintegrated into the
hydrogen production process. These materials could be used in new electrodes or other

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components, decreasing the dependency on new raw materials and reducing production
costs.
Environmental Benefits:
Reduction in Waste: Recycling degraded membranes reduces the volume of waste that would
otherwise end up in landfills or require incineration.
Conservation of Resources: Recovering and reusing materials conserves natural resources and reduces
the demand for new raw materials, promoting environmental sustainability.
4.1.4 Noise Pollution

Noise is produced whenever a mechanical part or an engine or motor is in operation. Particular plant
areas where noise levels are likely to be significant are:
 Reception storage and handling equipment
 Fuel preparation
 Feeding system
 The compressors, prolonged exposure to noise is well documented.
Adequate measures must be taken to minimize noise pollution. General Noise levels:
Serial Equipment Noise level (dB)

No.
1. Reception, storage and handling 80-120

equipment
2. Fuel preparation 85-110
3. The feeding system 70-75
4. Compressors 40-90

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4.2 Energy Conservation
The use of renewable resources like solar energy and biomass in hydrogen production from seawater
through polymer exchange membrane (PEM) electrolysis can offer a sustainable and environmentally
friendly method to generate hydrogen. Here's how these resources can be utilized:
 Solar Energy: Solar energy can power the electrolysis process. Photovoltaic (PV) panels can
directly convert sunlight into electricity, which can then be used to split water (H2O) into hydrogen
(H2) and oxygen (O2) via PEM electrolysis. This method, often referred to as "solar electrolysis,"
utilizes clean and renewable solar power to drive the electrolysis reaction.
 Biomass: Biomass can contribute in different ways. Biomass sources, such as organic waste or
dedicated energy crops, can be converted into biofuels like biogas. This biofuel can then be used
to generate electricity, which can, in turn, power the PEM electrolysis process for hydrogen
production.
 Wind Energy: Wind turbines can be installed near coastal regions to harness the energy from the
wind. This electricity can be used to power the electrolysis process, providing another renewable
energy source for hydrogen production. Wind energy can complement solar energy and provide
electricity during periods of low sunlight.
 Ocean Energy: Coastal areas can also utilize ocean energy technologies such as tidal and wave
energy. These technologies harness the kinetic and potential energy of ocean currents and waves
to generate electricity, which can be used for electrolysis. Ocean energy is particularly reliable and
can provide a consistent power source for hydrogen production.
 Geothermal Energy: In some coastal areas, geothermal energy may be available. Geothermal
power plants can tap into the Earth's heat to generate electricity. This geothermal electricity can be
used for seawater electrolysis, offering a steady and renewable source of energy.
 Hydropower: Coastal regions near rivers or waterways can make use of hydropower generated
from flowing water. Hydroelectric power can provide a consistent source of electricity for
hydrogen production, especially when combined with other renewable sources.
 Energy Storage Systems: Utilize energy storage systems, such as batteries or hydrogen storage,
to store excess energy generated from renewable sources during periods of high production. This
stored energy can then be used when renewable energy generation is low, ensuring a continuous
power supply for electrolysis.
Advantages of using renewable resources in this process include:

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 Environmentally Friendly: Renewable energy sources produce little to no greenhouse gas
emissions, reducing the carbon footprint associated with hydrogen production.
 Sustainability: Solar and biomass resources are sustainable and can be continually replenished,
unlike finite fossil fuels.
 Cost Reduction: Using renewable resources can potentially reduce operating costs over time, as
the ongoing costs of sunlight and biomass are generally lower than traditional energy sources.
Challenges and considerations for this method include:
 Efficiency: While renewable energy sources are clean, ensuring the efficiency of the conversion
process (from solar to electricity or biomass to electricity) is crucial for effective hydrogen
production.
 Technological Advancements: Further advancements in PEM electrolysis technology and the
integration of renewable resources are needed to enhance efficiency and reduce production costs.
 Infrastructure: Developing the infrastructure to support widespread implementation of these
systems, such as grid connections for solar energy and biomass supply chains, is essential.
Integrating renewable resources into hydrogen production using PEM electrolysis from seawater can
significantly contribute to a sustainable and clean energy future, offering a viable pathway towards
decarbonization and reduced dependence on fossil fuels.
5. Plant Utilities
In chemical process plants, plant utilities play a critical role in supporting the operation of the Facility.
Typical plan utilities include steam, electricity, refrigerants, inlet water sources, compressed air, Industrial
gasses, heat transfer fluids, cooling sewers, and more. Proper design, operation and maintenance of the
engineering systems needed to provide these items are key.
5.1 Air
Most of the units require a supply of air for maintenance.
There are usually two separate systems:
1 Process Air System

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2 Instrument Air System
Plant Air System:

A Plant may consist essentially of:
 Compressors with a power source

 Control system
 Intake air filter
 After cooler and separator
 Air receiver
 Air dryer
 Interconnecting piping
 Distribution system to carry the air to points of application
Atmospheric Air is sucked by air Compressor which basically contains water vapor & besides, in
lubricated type Air Compressors, oil is present in the air compression chamber traces of which are present,
in compressed air in Liquid/Vapor form, which condenses in a heavy gummy oil varnish. Condensed
moisture together with dust and oil in compressed air leads to emulsion formation causing many troubles.
The objective of installing an air system shall be to provide air to the various points of application in
sufficient quantity and quality and with adequate pressure for efficient operation of air tools or other
pneumatic devices.
5.1.1 Air for Process and Instrumentation:

Air is required to produce oxygen in the plant. To supply the process air an axial blower has been
installed in the plant. Plant air is available at B/L. for use at various service points and hose stations.
Instrument Air
Instrument air shall be dust-free, oil-free, and dry. To prevent condensation in the supply piping or in
the instruments, the dew point of the air at operating pressure shall always be at least 10°C lower than
the lowest ambient temperature ever recorded in the area. The required quantity of instrument air shall
be estimated considering the requirements for:
 Pneumatically operated instrumentation, based on the data provided by manufacturers or

suppliers of such equipment.

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 Pressurizing the enclosures of electrical instruments located in hazardous areas.
 Continuous dilution for enclosures of process stream analysers, etc.
Application in Our Plant:

Electrolyser Operation: Air is utilized for cooling and facilitating reactions during electrolysis, which
is the primary process for hydrogen production in our project.
Pneumatic Equipment: Compressed air powers pneumatic tools, valves, actuators, and control
systems essential for precise automation and operation of hydrogen production processes.
Controlled Environments: Air quality monitoring systems, powered by compressed air, ensure
regulatory compliance and maintain optimal conditions for hydrogen production.
Calibration and Measurement: Air is used in instrumentation for calibrating sensors, meters, and
analytical instruments, ensuring accurate measurements and process control.
5.2 Heat Transfer Media

Heating utilities are necessary for proper usage of distillers, reactors, condensers, and various other integral
types of equipment. Specifically, steam, fired heat, and hot heat transfer fluids are commonly utilized.
5.2.1 Steam as a Heat Transfer Medium

Steam is the most used heat utility in chemical plants, and understanding how it is utilized is essential
in the study of utility systems. Steam is used both as a process fluid and a utility. Here are a few
advantages of using steam compared to other methods of process heating:
 Control of Temperature: By controlling the pressure of the steam, one can control the
temperature at which the heat is released.
 Efficiency: Steam is an efficient heat source because the heat of condensation of steam is very
high.
 Cost-effectiveness: Heat exchangers that use steam are relatively cheap because condensing
steam has a high heat transfer coefficient.
 Safety: Steam is non-flammable, non-toxic, and inert to several process fluids.

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5.2.2 Steam Generation System
Chemical plants typically have a network of pipelines dedicated to providing steam. These networks
usually include steam at low pressure, medium pressure, and high pressure. In the diagram above,
boiler feed water at high pressure is preheated and supplied to other boilers.
These other boilers superheat the steam to create high pressure and high-temperature steam. The steam
is superheated past the dew point to account for heat loss in the pipelines. A portion of the high-pressure
steam is utilized for process heating in areas of the plant that require high temperatures. The remaining
high-pressure steam is converted into medium-pressure steam by valves and steam turbines. The
medium-pressure steam is then used to heat medium-temperature processes and to generate low-
pressure steam.
The low-pressure steam can be employed to heat low-pressure processes, and it can be expanded in
condensing turbines to generate shaft work and energy. In summary, steam serves a multitude of
purposes in a plant. High-pressure, medium-pressure, and low-pressure steam can all serve as heat
sources. Low-pressure steam has applications in electricity generation and various other uses.
5.3 Water
5.3.1 Process and General Water Requirements and Standards
Use of Raw Water:
A plant's water supply is divided into process, boiler feed, cooling, potable, fire water, and utility water
systems. Brief descriptions of the different water use in refineries are provided below:
 Process Water: Typically used for various purposes closely linked with hydrocarbons. Softened
water is commonly used for these purposes.
 Boiler Feed Water (BFW): Required for steam generation in a refinery, BFW needs to be treated
before use. The higher the steam pressure being generated, the higher the purity of BFW
required. In the Claus plant, BFW serves as an essential utility. It is used as a constant
temperature cooling medium in condensers where steam is generated. Additionally, it serves as
cooling media in the reaction furnace waste heat boiler (WHB) to cool down product gasses.
Moreover, it is utilized as heat recovery media in two waste heat boilers, generating low and
medium-pressure steam.
 Cooling Water: Water-cooled condensers, product coolers (heat exchangers), and other heat
exchangers can consume significant amounts of water in a refinery. Some refineries utilize air

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coolers, where the process stream is exchanged with air before being sent to a cooling water
heat exchanger. This approach minimizes the use of cooling water in the refinery.
 Potable Water: Potable water is necessary for use in kitchens, wash areas, bathrooms, safety
showers, and eyewash stations in refineries. City water or treated groundwater can fulfil this
requirement. In remote locations or small towns, a portion of treated water from the plant's
softening unit may be diverted for potable water use. The treated water must be chlorinated to
eliminate bacteria and then pumped into an independent system to prevent potential cross-
contamination. Potable quality water may also be required in certain specialist chemical
operations, such as dilution purposes.
 Fire Water: Fire water requirements in refineries are intermittent but can constitute a substantial
flow. Often, refineries collect stormwater from non-process areas and store it in a reservoir
dedicated to the fire water system. Provisions are typically made for a connection of the fire
water system to the largest available water reservoir in emergency situations. Usually, this is
the raw water supply since fire water requires no treatment. Plants located along coastal areas
often use seawater or brackish water as fire water.
 Utility Water: Utility water is utilized for various washing operations, such as cleaning
operating areas. It should be free from sediment but does not require any additional treatment.
Application in Our Project:
 Cooling Systems: Water is circulated through cooling systems to dissipate heat generated
during hydrogen production processes, ensuring equipment integrity and efficiency.
 General Facility Use: Water is used for cleaning equipment, maintaining hygiene standards,
and meeting general facility requirements.
 Water Treatment: Treatment facilities ensure water quality, preventing contamination and
safeguarding equipment from corrosion and scaling.
5.3.2 Water Treatment and Storage Facilities:

Raw water treatment in a refinery generates wastewater and sludge that require disposal. The following
section outlines best practices regarding these discharges.
 Lime Softening: When lime softening is employed for raw water treatment, the generated
sludge should be thickened and optionally dewatered. The overflow water from the thickener

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can be discharged directly if local regulations permit. The generated sludge should be disposed
of off-site to prevent the introduction of inert solids into the refinery sewer system.
 Wastewater Stream and Acidic Wastewater Stream: As a result of the regeneration of exchange
beds, a wastewater stream and an acidic wastewater stream are generated. These streams should
be collected in a tank, and the pH neutralization process should occur before discharge. If
allowed by regulations, they can be discharged directly to an outfall, bypassing wastewater
treatment.
 Reverse Osmosis: The use of reverse osmosis for raw water treatment generates a reject stream
with high dissolved solids. This reject stream should be discharged directly to an outfall,
bypassing wastewater treatment, if permitted by local regulations.
 Sour Water Treatment: Sour water is typically treated by sending it to a stripper for the removal
of hydrogen sulphide (H2S) and carbon dioxide (CO2). Steam injection is used to provide heat
to the strippers. High-performance strippers can achieve levels of less than 1 ppm H2S and less
than 30 ppm CO2 in the stripped sour water. In the sour water stripper, all the sour water
produced in the refinery is flashed in a drum, and any separated oil is sent to refinery slops.
The vapours from this drum are sent to the flare. The sour water from the drum is then directed
to a storage tank to provide the required surge in the system. It is subsequently passed through
a feed/bottoms exchanger where it is heated before being sent to the stripper. The separated
vapours containing H2S, and CO2 are sent to the sulphur plant. The stripped water is routed
for reuse in the refinery via the feed/bottom's exchanger and a trim cooler. Any excess water
that cannot be reused is directed to a wastewater treatment plant.
Water Storage:
Water storage facilities serve several purposes within a distribution system. The main purposes of
finished water storage include:
 Equalizing supply and demand

 Increasing operating convenience
 Levelling out pump requirements
 Decreasing power costs
 Providing water during power source or pump failure
Increasing Detention Times: Increasing detention times in water storage facilities can help improve
water quality by allowing for better settling of suspended solids and disinfection of microorganisms.

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This can be achieved by adjusting the design and operation of the storage facilities to ensure that water
remains in the storage tanks for longer periods before being released into the distribution system.
Blending Water Sources: Blending water from different sources can help optimize water quality and
ensure a reliable supply. By mixing water from various sources, it is possible to achieve the desired
chemical composition and reduce the risk of contamination or shortages. This practice is often used in
water treatment plants to balance the characteristics of different water sources and meet regulatory
requirements.
Boiler Feed Water: Raw water used as boiler feed water needs to be demineralized to prevent corrosion
and scaling of pipelines and equipment. This process typically involves several steps in the water
treatment plant, including:
1. Removal of chlorine in an activated carbon bed.
2. Demineralization using weak acid cation (WAC), strong acid cation (SAC), weak base anion
(WBA), and strong base anion (SBA) exchange resins.
3. Removal of CO2.
4. Regeneration of the exchange beds.
5. Polishing of the demineralized water in mixed bed units.
5.4 Refrigeration
Utility Description:
Refrigeration systems are designed to cool or maintain low temperatures in various applications, including
air conditioning and refrigeration.
They utilize the principles of thermodynamics to transfer heat from a low-temperature environment to a
higher-temperature environment, typically using refrigerants.
Application in Our Project: While refrigeration is not directly utilized in our green hydrogen production
project, it can be mentioned hypothetically as follows:
Potential Application for Temperature Control:
Although not currently utilized in our project, refrigeration systems could be considered for maintaining
specific temperatures in certain process stages if required in future expansions or modifications.

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They could potentially be employed for cooling purposes in storage facilities or environmental control
systems to ensure optimal conditions for equipment and personnel comfort.
5.5 Electricity/Power
Power is essential for various operations in the plant, including powering pumps, compressors, lighting,
and control systems. A substation within the plant is necessary for distributing power effectively. Many
plants utilize captive power plants where steam pressure is reduced in turbines to generate electricity for
plant operations. Grid power can be purchased if additional power is needed. Key areas of electricity
consumption in the plant include:
 Operation of pumps, blowers, and compressors.
 Powering the control room for plant operations.
Application in Our Plant:
Electrolyser Operation: Electricity is the primary energy source for powering the electrolysis process,
where water is split into hydrogen and oxygen gasses.
It drives the electrolyser, providing the electrical current necessary for the electrolysis reaction to occur.
6. Organizational Structure and Manpower Requirement

6.1 Organizational Structure
Abstract
An organizational structure has been developed simulating various other big chemical industries in India.
Various principles of organization, hierarchy structure with organization chart have been discussed.
Various sections within a plant have been described along with total manpower requirements.

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Introduction
Organization is a structured process in which individuals and groups of people interact, that is, act and
react continuously to achieve stated objectives. It is a structure as well as a process or a group of on-going
activities. Interaction and interrelationship of members in an organization to achieving some purpose
represents the human aspect of an organization.
Principles of Organization are following-
1. There should be a clear line of authority from top to bottom. Though each individual should be
responsible to one person only, he should have access to his higher authorities.
2. Responsibility must be allied with the authority.
3. The span of control of an executive must be limited to the number of subordinates whose activities
can be coordinated effectively.
4. Over organization must be avoided.
The organization structure of our unit can be classified into: -
a) Top management organization
b) Operating line management
The top management organization of the company is of the staff type with level of management differing
with the functions and responsibility of the individual. It consists of the general management or
administrative personnel who in turn control and manage the divisional or departmental management
personnel. In the top management, the board of directors is to represent, safeguard, and further the
stockholders' interests, determine the basic policies and the general course of business appraise the
adequacy of overall results and in general protect and make most effective use of the company assets.
The organization must have certain principles: -

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1. All functions and tasks should be properly allocated to different persons and the points of action should
be clearly made known to them.
2. The points of actions and decisions should be as clear as possible.
3. Grouping of functions reduces the delay in execution of work.
4. The duties, responsibilities and discretionary limits of each person should be made quite clear.
The number of supervisory levels must be as small as possible.
DEPARTMENTS
General Administration
The organization will be headed by a general manager. He will perform a number of duties:
a) Take prompt and important decisions so as to simplify the execution of work.
b) Ensure smooth running of the factory with maximum profit.
c) Plan and implement a diversification program.
d) Keep coordination between various departments.
He will have broad, overall responsibility for the business or organization. Whereas, the manager may be
responsible for one functional area, the General Manager is responsible for all areas. General Managers
manage through subordinate managers. However, a General Manager may have individuals reporting to
him/her who are not managers. He has the power to hire, fire, or promote employees. The General Manager
will be responsible for higher level planning. A General Manager is often responsible for the overall
strategic planning and direction of the company or organization and leaves the day-to-day management of
the various functions to the managers.
Production Division
This department is headed by a production manager. He must be a technical person and is responsible for
overall production and smooth functioning of the plant. Production is the Section responsible for turning
inputs into finished outputs through a series of production Processes. The production manager is
responsible for making sure that raw materials are provided and made into finished goods effectively.
He/she must make sure that work is carried out smoothly and must supervise procedures for making work
more efficient and more enjoyable.
Production and Planning Department

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The production and planning department will set standards and targets for each section of the production
process. The quantity and quality of products coming off a production line will be closely monitored in
businesses focusing on lean production, quality will be monitored by all employees at every stage of
production, rather than at the end as is the case for businesses using the quality control approach.
Design and Technical Support Department

The design and technical support department will be responsible for researching new products or
modifications to existing ones, estimating costs for producing in different quantities and by using different
methods. It will also be responsible for the design and testing of new product processes and product types,
together with the development of the prototypes through to the final product. The technical support
department may also be responsible for work study and suggestions as to how working practices can be
improved.
Safety Division
A Vice President heads the safety division of the plant. Aim of this department is to ensure all activities
are carried out safely and to conduct safety training sessions for the employees and labourers, to conduct
safety audits and ensure proper functioning of safety equipment.
Marketing Division
One of the most important functions of a marketing division is to design a set of written goals, objectives
and strategies for marketing activities of the organization. This means establishing rules and business
concept of how the organization will conduct itself on the market, what marketing instruments will be
used, what goals will be set and what strategies should be applied to attain effective advertising campaigns.
This marketing department develops a market-based business strategy that provides unique value to the
customers on all services and products of the organization. This department is headed by a marketing
engineer. He is responsible for the development of new marketing strategies and also the publicity,
advertising, sales and complaints related to the product.
Finance Division
When it comes to the overall scope and duties of a finance department, there are many functions to be
fulfilled. For the most part, the duties include all things related to budgeting. From appropriations to

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control of expenditure and auditing duties, the finance department of any given company has an array of
duties.
A finance department basically has five main functions:
1. Bookkeeping procedures
2. Creating a balance sheet and profit and loss account
3. Providing management information
4. Management of wages
Human Resources
Human Resources of personnel's main responsibility is the recruitment, selection, training and
development of the staff. This will involve developing staff to maximize their potential in manner that
furthers the organization's objectives. Human Resources often adapts a welfare role which includes
looking after employees whilst they are at work. They may also create policies that balance
organizational needs with those of the employees. They will also interpret employee welfare legislation
and ensure that the organization is complying with the applicable legislation.
The tentative salary distribution is calculated with the help of operating labour/day vs plant
capacity/day plot for chemical industries, considering average conditions.

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Capacity: 4.75 TPH
Daily Capacity: 4.75*24 = 114 TPD (Segment B as Average Condition)
Designation Requirement Salary/month Qualification
President 1 4,00,000 Engineer+MBA+15-year onsite experience

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Production Department
Vice president 1 3,00,000 Engineer + MBA + 10 years of experience
Production Manager 1 2,50,000 Chemical Engineer with 10 years of experience
Manager Operations and 1 2,00,000 Industrial/Mechanical Engineer with 10 years of

Maintenance experience
Manager raw material and 1 1,75,000 Pni/Mechanical Engineer with 8 years of work
stores experience
Manager quality and 1 1,75,000 Pni/Mechanical Engineer with 8-10 years of work
Testing experience
Production Engineer 2 1,00,000 Chemical Engineer with 4 years of work

experience
Maintenance Engineer 4 1,00,000 Mechanical Engineer with 4 years of work

experience
Instrumentation Engineer 2 1,00,000 Instrumentation Engineer with 4 years of work

experience
Shift Engineer 10 75,000 Chemical Engineer with 4 years of work

experience
Shift operators 15 50,000 Diploma in Chemical Engineering

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Deputy Manager fire and 2 90,000 8 years of experience in fire and safety
Safety management
Deputy Manager 1 75,0000 Graduate with 4 years of experience in public

Environment safety relations
Medical officer 2 1,00,000 MBBS with 4 years of experience
Medical Staff 4 50,000 Diploma
Marketing Department
Vice President 1 3,00,000 MBA (marketing) with 10 years of experience
Manager Sales 1 2,00,000 MBA (marketing) with 8 years of experience
Manager Marketing 1 2,00,000 MBA (marketing) with 8 years of experience
Manager Purchase 1 2,00,000 MBA (marketing) with 8 years of experience
Marketing Officer 5 1,00,000 MBA (marketing) with some or no experience
Finance Department
Vice President 1 3,00,000 CA with 10 years of experience
Manager Finance 1 2,00,000 MBA (fin) with 8 years of experience

101
Manager Accounts 1 2,00,000 CA with 8 years of
Clerical Staff 1 60,000 B.com with some or no experience
Human Resources Department
Vice President 1 2,00,000 MBA with 10 years of experience
Manager Administration 1 1,75,000 MBA with 10 years of experience
Manager Training 1 1,75,000 Engineer MBA with 10 years of experience
Deputy Manager security 2 85,000 Retired army or Police official
Deputy Manager Public 2 75,000 Graduate of 5 years of experience in Public

Relations Relations
Staff and Labour
Labour 50 25,000 On contract and basic school qualification
Librarian 1 80,000 Master’s degree in library science
Library Staff 2 55,000 Bachelor’s degree in library science
Total skilled employee: 70; Total unskilled employee: 50; Total organization cost/month: 75 lakhs
(approx.); Total organization cost per annum: 9 crores (approximately)

102
7. Market Prospects
7.1 A brief analysis of demand and supply of green hydrogen
The time is ripe to tap into hydrogen’s potential contribution to a sustainable energy system. In 2019, at
the time of the release of the IEA’s landmark report The Future of Hydrogen for the G20, only France,
Japan and Korea had strategies for the use of hydrogen. Today, 17 governments have released hydrogen
strategies, more than 20 governments have publicly announced they are working to develop strategies, and
numerous companies are seeking to tap into hydrogen business opportunities. Such efforts are timely:
hydrogen will be needed for an energy system with net zero emissions. In the IEA’s Net Zero by 2050: A
Roadmap for the Global Energy Sector, hydrogen use extends to several parts of the energy sector and
grows sixfold from today’s levels to meet 10% of total final energy consumption by 2050. This is all
supplied from low-carbon sources.
While the adoption of hydrogen as a clean fuel is accelerating, it still falls short of what is required to help
reach net zero emissions by 2050. If all the announced industrial plans are realized, by 2030:
 Total hydrogen demand could grow as high as 105 Mt – compared with more than 200 Mt in the NZE
Scenario
 Low-carbon hydrogen production could reach more than 17 Mt – one-eighth of the production level
required in the NZE Scenario
 Electrolysis capacity could rise to 90 GW – well below the nearly 850 GW in the NZE Scenario

103
 Up to 6 million FCEVs could be deployed – 40% of the level of deployment in the NZE Scenario (15
million FCEVs)
7.2 Present production capacity/licenced capacity in the country giving the status of the production
The selection of PEM/AWE method would be preferred as they are already being commercially produced.
India aims for annual production of 5 million metric tons of green hydrogen by 2030, which would cut
about 50 million metric tons of carbon emissions and save more than $12 billion on fossil fuel imports.
7.3 Marketing set-up and area of consumption

China, India, Japan, South Korea, Europe, and North America are likely to account for 75 percent of global
hydrogen demand, with China emerging as the largest consumer in the years to come. China is likely to
be the largest single market for clean hydrogen by 2050 with an estimated demand for 200 million tons
(MT) of clean hydrogen, followed by Europe and North America, each generating a demand for 100 MT
of clean hydrogen; India with 55 MT; and Japan and South Korea with 35 MT.

104
Clean hydrogen deployment involves four major outliers:
Supply: About 800 kt p.a. clean hydrogen supply is operational globally, up from about 700 kt p.a. About
740 kt p.a. is low-carbon hydrogen (primarily in North America), and the remainder is renewable. In
addition to this volume, about 2 Mt p.a. has passed FID, of which more than half is low-carbon hydrogen.
Infrastructure: Infrastructure deployment is progressing and is critical to ensure that (low-cost) clean
hydrogen supply matches the demand. Committed investments in hydrogen infrastructure have grown
from about USD 5 billion to about USD 7 billion, of which more than three-quarters are in Asia.
Hydrogen end use: Committed investments into hydrogen end uses increased by about USD 0.5 billion,
with the most growth in North America. Within mobility, cumulative FCEV sales now stand at about
80,000 vehicles, up 30%, representing annual sales of about 17,000 vehicles in 2022 – less than 1% of

105
global vehicle sales. Vehicle OEMs have announced more than 130 FCEV models expected to be
assembled in 2023, of which the majority consists of commercial vehicles (trucks, buses) in China.
Manufacturing capacity: Electrolyser and fuel cell manufacturers are readying for scaling up. According
to OEM statements, growth in electrolyser manufacturing capacity has reached nearly 9 GW, a growth of
150%. For fuel cell manufacturing, the total global capacity stated by OEMs stands at 12 GW, with Japan
and South Korea as the largest supply markets.
Export potential
Considering the renewable energy potential and the enabling framework proposed under the Mission,
India’s Green Hydrogen production costs are expected to be among the lowest in the world. A global
demand of over 100 MMT of Green Hydrogen and its derivatives like Green Ammonia is expected to
emerge by 2030. Many countries are likely to rely on imports due to constraints on land and renewable
resources required to produce Green Hydrogen domestically. Aiming at about 10 per cent of the global
market, India can potentially export about 10 MMT of Green Hydrogen/Green Ammonia per annum.
The enabling framework created under the Mission and support for hydrogen hubs and port infrastructure
will facilitate the development of a vibrant export market. Growth in the export market will have a positive
cascading effect on domestic production as well. The Mission will facilitate the development of strategic
international partnerships to enable the export of green hydrogen and its derivative products.
8. Site Selection & Project Layout

Selecting the right location for the green hydrogen plant is a crucial step as it contributes to the success
and sustainability of the project in the long run. A few factors to consider when evaluating the potential
locations are:
 Access to Renewable Resources: Green hydrogen production relies on renewable energy sources such
as solar or wind power. Therefore, selecting a site with abundant and reliable renewable energy
resources is essential to ensure continuous and cost-effective hydrogen production.
 Infrastructure Availability: The chosen site should have access to necessary infrastructure like water
supply, electricity grid connections, transportation networks (roads, railways, ports), and industrial
facilities. Access to these amenities can streamline the construction process and reduce operational
costs.

106
 Environmental Considerations: Site selection must consider environmental factors such as air quality,
water availability, biodiversity, and land use. Minimizing the environmental impact of the production
process is essential for sustainability and regulatory compliance.
 Economic Viability: The economic feasibility of the project heavily depends on the chosen site. Factors
like land cost, labour availability, taxation policies, and proximity to markets can significantly impact
the overall cost structure and profitability of the hydrogen production plant.
 Regulatory and Permitting Requirements: Different locations may have varying regulatory
frameworks and permitting processes governing industrial activities. Selecting a site with favourable
regulations and streamlined permitting procedures can expedite project development and reduce
regulatory risks.
 Market Access: Proximity to potential customers or end-users of hydrogen and hydrogen-based
products is crucial for market penetration and competitiveness. Choosing a site close to existing or
emerging markets can reduce transportation costs and enhance market access.
 Strategic Considerations: Strategic factors such as geopolitical stability, geopolitical risk, and
proximity to key suppliers or partners may also influence site selection decisions. These factors can
impact long-term operational resilience and business continuity.
States with extensive coastal regions and strong renewable energy potential are well-suited for setting up
green hydrogen production industries utilizing seawater. Some states in India that fit these criteria include
Gujarat, Maharashtra, Tamil Nadu, Karnataka, Kerela but Gujarat and Tamil Nadu stand out for their
extensive coastline and strong solar and wind energy resources. Gujarat and Tamil Nadu have historically
been proactive in implementing supportive policies and offering incentives for renewable energy and
industrial development. Gujarat boasts well-developed infrastructure, including ports along its coastline,
which can facilitate the import of equipment and export of hydrogen. Gujarat and Karnataka have been
recognized for their efforts to improve the ease of doing business and simplify regulatory procedures.
Considering these factors, Gujarat emerges as a strong contender for establishing a green hydrogen
production industry because of the various strategic advantages that it offers. Its extensive coastline,
abundant renewable energy resources, supportive government policies, well-developed infrastructure, and
strategic location make it a favourable choice.
In Gujarat, several cities offer strategic advantages for setting up a green hydrogen plant based on factors
such as renewable energy potential, infrastructure, access to resources, and industrial ecosystem. Some of
the best cities to consider are Jamnagar, Munda, Bhavnagar, Surat, Ahmedabad, Gandhinagar.

107
Jamnagar, Gujarat, stands as the ideal locale for green hydrogen production plant considering the following
points:
Firstly, Gujarat's abundant renewable energy potential, particularly in solar and wind resources, provides
us with the necessary green energy input for hydrogen production through electrolysis.
Secondly, Jamnagar's well-established industrial infrastructure, honed by its history in oil refining and
petrochemicals, offers a solid foundation upon which to build our green hydrogen facilities efficiently.
Thirdly, situated along the coast, Jamnagar provides seamless access to shipping routes, facilitating both
the import of essential equipment and resources and the export of our green hydrogen products.
Moreover, the proactive stance of the Indian government, with initiatives like the National Hydrogen
Mission, further propels our decision, ensuring a supportive regulatory environment and access to
incentives for our endeavours.
In addition, the burgeoning global demand for clean energy solutions underscores the strategic importance
of establishing our operations in Jamnagar, positioning us to meet both domestic and international needs
effectively.
Lastly, the existing industrial ecosystem in Jamnagar offers invaluable synergies, potentially optimizing
our processes and enhancing overall efficiency through collaborative ventures.
In summation, the combination of renewable energy abundance, robust infrastructure, government

support, strategic location, global demand, and industrial synergy renders Jamnagar, Gujarat, the premier
choice for green hydrogen production venture.

108
Plant Layout
9. Economic Evaluation & Profitability of the Project

To enhance investment and spending revenue, a more equitable distribution of resources is the goal of the
project's economic study. An economically viable system that can function in profitable conditions should
be introduced by a plant design that is deemed acceptable. The durability of project outcomes is a
prerequisite for economic sustainability. If a project's benefits and positive outcomes continue as
anticipated for the duration of the project, then it is considered sustainable. A Chemical Engineer must be
knowledgeable of the many types of expenses associated with production processes since Net Profit is
calculated as total income less all costs.

109
An economic assessment of the first proposed plant project will provide compelling reasons to improve
design. Before investors agree to spend a lot of money funding for the proposed project, management must
ensure that the project will provide sound investment. So the economic process is just as important as the
design process itself. Net payback period, Total future value, Total current value and rate of return on
investment will be considered in detail. Based on these indications as to whether the proposed design will
be evaluated.
Cost Estimations
The primary goal of the methanol production plant is to make profit, and an estimate of the investment
required is needed earlier than the profitability of this mission may be evaluated. Value estimation could
start with the estimation of the capital costs. This will then be accompanied by using running price
estimates and finally based on those; the profitability signs of the design challenge are anticipated.
Capital Cost Estimates
Two primary components in capital cost estimation are
1. Fixed Capital
2. Working Capital
Fixed Capital:
Fixed capital consists of assets that are not consumed or destroyed in the production of a good or service
and can be used multiple times. Property, plant, and equipment are standard fixed capital items. In Our
case it can be defined as the total cost of designing, constructing, and installing a plant and the associated
modifications needed to prepare the plant site. In simple terms it can be defined as the sum of Direct and
Indirect Cost
Direct Costs:
1. Purchased equipment: Columns, Heat Exchangers, tanks, etc.
2. Equipment Installation
3. Piping (includes insulation)
4. Instruments and Control
5. Electrical Equipment.

110
6. Buildings: Process, Administration, Maintenance shops, etc.
7. Site Preparation
8. Service Facilities: steam, water, air, fuel, etc. Waste treatment, fire control, offices, etc.
9. Land
Indirect Costs:
1. Engineering and Supervision: Administrative and Design. Supervision and Inspection.
2. Construction Expenses
3. Contractor's fee
4. Contingency
5. Start-up expenses
Working Capital
Working capital represents short-term assets available to a business for meeting financial obligations such
as payroll, creditors, and suppliers. A company with insufficient working capital can have liquidity
problems even when their asset position and profitability is healthy. In simple terms it can be defined as-
Working Capital= Receivables + Inventory – Payables + Cash on hand
Step: 1
Equipment Purchasing Cost
Purchased equipment costs are crucial for a project's initial development and budgeting. The actual cost
of a piece of equipment depends upon many factors. References for evaluating equipment cost are as
follows:
1. Coulson and Richardson’s, Volume 6, 4th Edition
2. Matches process Equipment Cost Estimates.
3. CAPCOST Software-CAPCOST software calculates the total cost of equipment based
upon its specifications such as wall thickness, diameter, length, operating pressure, etc.

111
4. Some important considerations are:
- The base year taken is 2002.
- All the equipment is scaled to the present worth using the ‘Chemical Engineering Plant Cost Index’
published regularly in the Chemical Engineering Magazine
𝑃𝒓𝒆𝒔𝒆𝒏𝒕 𝑪𝒐𝒔𝒕 = 𝑶𝒓𝒊𝒈𝒊𝒏𝒂𝒍 𝑪𝒐𝒔𝒕*(𝒊𝒏𝒅𝒆𝒙 𝒗𝒂𝒍𝒖𝒆 𝒂𝒕 𝒑𝒓𝒆𝒔𝒆𝒏𝒕 𝒕𝒊𝒎e 𝒊𝒏𝒅𝒆𝒙/𝒗𝒂𝒍𝒖𝒆 𝒂𝒕 𝒕𝒉𝒆 𝒕𝒊𝒎𝒆
𝒐𝒓𝒊𝒈𝒊𝒏𝒂𝒍 𝒄𝒐𝒔𝒕 𝒘𝒂𝒔 𝒐𝒃𝒕𝒂𝒊𝒏𝒆𝒅)
The most recent available Chemical Engineering Plant Cost Index (CEPCI) value is for the year 2021,
which was published in the April 2022 issue of Chemical Engineering Magazine.
Year Index
2002 390.4
2021 776.9
Table: Cost Index
Equipment Name Price in INR (2002) Price in INR (2021)
Heat Exchanger 8,50,000 1691508
Cooler 1 4,30,000 855704
Cooler 2 5,10,000 1014905
PEM Electrolyser 56,60,000 11263457
RO Unit 3,46,600 689737
Mixer 3,00,000 597003

112
Pump 1 47,000 93530
Demister 1 2500 4976
Demister 2 3500 6966
Purchased Equipment Cost = 16,217,786
Step: 2
Other Direct Costs:
1. Instruments and Controls: Include Components like safety valves, pressure control,
temperature control, etc.
2. Piping: Pipes used in plants like GI, MS, etc., and their fitting material for insulation
3. Utilities and Facilities: Utilities like compressors, generators, boilers, etc are covered
in this section.
4. Non-Process Equipment: these are essential for company work purposes like fire
extinguishers.
5. Electrical Equipment: switches, motors, wires, fittings, etc.
6. Construction of Building:
1. Process buildings
2. Auxiliary buildings
3. Maintenance shops
4. Building Services -Plumbing work (labour charges), Air Handling Units (HVAC),
Paint Material Labour charges for painting.
7. Site Development: It includes the following factors:

113
1. Site Clearing
2. Roads
3. Walkways
4. Landscaping
Step 2A : Direct Costs
Item Percent of Purchased Cost Cost In INR
Purchased Equipment Cost 100 16217786
Purchased Equipment Installation 45 7315914
Instruments and Controls 13 2113486
Piping 30 4877276
Electrical Equipment 15 2438638
Building 30 4877276
Yard Improvements 10 1625758
Service Facilities 35 5690155
Land 6 975455
Civil Architecture 20 3251517
Total Direct Cost = 4,94,23,066
Step 2B: Indirect Costs

114
Item Percent Of Purchased Cost Cost In INR
Engineering and Supervision 32 5202428
Construction Expenses 34 5527579
Contractor’s Fee 18 2926365
Contingency 36 5852731
Legal Expenses 4 650303
Total Indirect Cost = 2,01,59,408
Step 2C: Total Capital Investment
Description Cost In INR
Total Indirect Cost(I) 20159408
Total Direct Cost(D) 49423066
Fixed Capital(D+I) 69582475
Working Capital (20% of FC) 13916495
Start-Up Cost (10% of FC) 6958247
Total Capital Investment 16,00,39,693
Step: 3 Total Product Cost

115

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TECHNO-ECONOMIC ANALYSIS FOR PRODUCTION OF

4.75 TPH GREEN HYDROGEN THROUGH WATER ELECTROLYSIS

B. TECH PROJECT REPORT

AYUSH YOGESH PATIL (20121007)

DEPARTMENT OF CHEMICAL ENGINEERING

SUPERVISOR: PROF. B. PRASAD

Dr. Basheshwar Prasad

Department of Chemical Engineering

Indian Institute of Technology, Roorkee

DEPARTMENT OF CHEMICAL ENGINEERING, IIT ROORKEE

Enrolment No. 20410023

Department of Chemical Engineering

Indian Institute of Technology Roorkee

DEPARTMENT OF CHEMICAL ENGINEERING, IIT ROORKEE

DEPARTMENT OF CHEMICAL ENGINEERING, IIT ROORKEE

2.1 Process Summary ..................................................................................................................................... 6

2.2 Plant Location Summary .......................................................................................................................... 7

2.3 Organizational Summary.......................................................................................................................... 8

3. Project Details ................................................................................................................................................ 7

3.1 Introduction ........................................................................................................................................ 7

3.2 Project Description............................................................................................................................. 8

3.2.1 Uses and present status of hydrogen .............................................................................................. 8

3.2.2 Process Information ..................................................................................................................... 12

3.2.3 Raw Materials .............................................................................................................................. 25

3.3 Material and Energy Flow Information ........................................................................................... 37

3.4 Detailed Design of Equipment ......................................................................................................... 44

3.4.1 Process Design ............................................................................................................................. 44

3.4.2 Mechanical Design....................................................................................................................... 61

3.4.3 Mechanical Drawing .................................................................................................................... 67

3.4.4 Specifications of process equipment ............................................................................................ 68

3.4.5 Engineering problems and their possible remedies ..................................................................... 71

3.5 Material Storage & Handling Facilities ........................................................................................... 74

3.5.1 H2 (Hydrogen) ............................................................................................................................. 74

3.5.2 Seawater ....................................................................................................................................... 77

3.5.3 Oxygen ......................................................................................................................................... 78

3.6 Process Instrumentation & Control and Safety Aspects .................................................................. 79

4. Environmental Protection & Energy Conservation ..................................................................................... 81

4.1 Environmental Aspects .................................................................................................................... 81

4.1.1 Air Pollution................................................................................................................................. 81

4.1.2 Liquid Effluents ........................................................................................................................... 81

DEPARTMENT OF CHEMICAL ENGINEERING, IIT ROORKEE

4.1.4 Noise Pollution............................................................................................................................. 85

4.2 Energy Conservation ........................................................................................................................ 86

5. Plant Utilities ............................................................................................................................................... 87

5.1 Air .................................................................................................................................................... 87

5.1.1 Air for Process and Instrumentation: ........................................................................................... 87

5.2 Heat Transfer Media ........................................................................................................................ 89

5.2.1 Steam as a Heat Transfer Medium ............................................................................................... 89

5.2.2 Steam Generation System ............................................................................................................ 89

5.3 Water ................................................................................................................................................ 90

5.3.1 Process and General Water Requirements and Standards ............................................................ 90

5.3.2 Water Treatment and Storage Facilities: ...................................................................................... 91

5.4 Refrigeration .................................................................................................................................... 93

6. Organizational Structure and Manpower Requirement ............................................................................... 94

6.1 Organizational Structure ................................................................................................................ 894

7. Market Prospects ........................................................................................................................................ 103

7.1 A brief analysis of demand and supply of green hydrogen............................................................ 103

7.3 Marketing set-up and area of consumption .................................................................................... 104

8. Site Selection & Project Layout ................................................................................................................. 106

9. Economic Evaluation & Profitability of the Project .................................................................................. 109