Carbon-Free Hydrogen and Electricity From Coal: Options for Syngas Cooling in Systems Using a Hydrogen Separation Membrane Reactor Available to Purchase

Conversion of coal to carbon-free energy carriers, H₂ and electricity, with CO₂ capture and storage may have the potential to satisfy at a comparatively low cost much of the energy requirements in a carbon-constrained world. In a set of recent studies, we have assessed the thermodynamic and economic performance of numerous coal-to-H₂ plants that employ O₂-blown, entrained-flow gasification and sour water-gas shift (WGS) reactors, examining the effects of system pressure, syngas cooling via quench versus heat exchangers, “conventional” H₂ separation via pressure swing adsorption (PSA) versus novel membrane-based approaches, and various gas turbine technologies for generating co-product electricity. This study focuses on the synergy between H₂ separation membrane reactors (HSMR) and syngas cooling with radiant and convective heat exchangers; such “syngas coolers” invariably boost system efficiency over that obtained with quench-cooled gasification. “Conventional” H₂ separation requires a relatively high steam-to-carbon ratio (S/C) to achieve a high level of H₂ production, and thus is well matched to relatively inefficient quench cooling. In contrast, HSMRs shift the WGS equilibrium by continuously extracting reaction product H₂, thereby allowing a much lower S/C ratio and consequently a higher degree of heat recovery and (potentially) system efficiency. We first present a parametric analysis illuminating the interaction between the syngas coolers, high temperature WGS reactor, and HSMR. We then compare the performance and cost of six different plant configurations, highlighting: 1) the relative merits of the two syngas cooling methods in membrane-based systems, and 2) the comparative performance of “conventional” versus HSMR-based H₂ separation in plants with syngas coolers.