Hydrogen Production from Natural Gas (Partial Oxidation Process)
Hydrogen Production Costs Report | Issue C | Q3 2024
Report Details |
25 MM Nm3/y United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 25 MM Nm3/y (MM Nm3 per year) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This study provides a techno-economic study of Hydrogen production from natural gas in the United States. In this analysis, natural gas is submitted to a thermal partial oxidation process, producing syngas, which is passed through a shift converter to enrich the Hydrogen output.
The report provides a comprehensive study of Hydrogen production and related Hydrogen production cost, covering three key aspects: a complete description of the Hydrogen production process examined; an in-depth analysis of the related Hydrogen plant capital cost (Capex); and an evaluation of the respective Hydrogen plant operating costs (Opex).
The Hydrogen production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Hydrogen plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Hydrogen plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic

The process under analysis comprises four major sections: (1) Sulfur Removal; (2) Partial Oxidation; (3) Water-gas Shift; and (4) Purification.
Sulfur Removal. Natural gas feedstock is purified by catalytic treatment with recycled hydrogen for removal of sulfur impurities. A pressurized mixture is fed to a hydrotreater with platinum-based catalyst, where hydrogen reacts with sulfur compounds present in the feed stream forming hydrogen sulfide, which is then adsorbed in zinc oxide beds in the desulfurizer.
Partial Oxidation. Purified natural gas is partially oxidized by being mixed with pressurized air in the Partial Oxidation (POX) Reactor, forming CO and hydrogen. Steam is also fed in the reactor to promote a CO shift reaction, in which carbon monoxide reacts with water, generating carbon dioxide and more hydrogen.
Water-gas Shift. Steam is added to the POX Reactor outlet stream, and reacts with the bulk of the carbon monoxide still present in it, forming Hydrogen and carbon dioxide. The shift conversion is firstly carried out in a high temperature (350-400 °C) reactor, over a bed of iron oxide/chromium oxide catalyst, and then in a low temperature (200-220 °C) reactor, in the presence of a catalyst containing copper oxide, zinc oxide and aluminum oxide.
Purification. The shifted gas is then cooled to near ambient temperature, causing water to condense, which is then removed in a knockout drum. Carbon dioxide and other impurities are removed from the hydrogen stream in a pressure swing adsorption (PSA) system. A small portion of pure hydrogen is recycled to the Sulfur Removal section, and the remainder is compressed and sent to storage facilities.
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Hydrogen production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Hydrogen process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Hydrogen production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Hydrogen plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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