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INTEGRATED LABORATORY SCALE DEMONSTRATION EXPERIMENT OF THE HYBRID SULPHUR CYCLE AND PRELIMINARY SCALE-UP specifications. However between these extremes of capital investment estimates, there can be numerous methods which can be divided into the following categories (Chauvel, 2000): • For a pre-design stage: – “Order of magnitude estimate” also called “ratio estimate”. This method considers economic data for reference equipment and supposes that required pieces of equipment are very similar to the reference ones (in size range, materials, temperature and pressure operating range, etc.). The order of magnitude estimate uses ratios based upon specific size or equipment capacity. For such an estimate, the accuracy is about ±40-50%. – “Study estimate” also called “factored estimate”. When studies are more advanced, the factored estimate may take into account the detailed equipment characteristics. Once the individual costs are determined, they may be multiplied by a number of factors for installation, piping and services, instrumentation and control and eventually by date and geographic location factors. Probable accuracy of estimate is about ±25-30%. • For construction: – “Design estimate” (budget authorisation estimate or scope estimate) based on a semi-detailed analysis. This approach incorporates a mixture of different methods with probable accuracy within ±15/20%. – “Detailed estimate” (contractor’s estimate) based on complete engineering drawings, specifications and site surveys. Probable accuracy of estimate is about ±5%. Flow sheets of the chemical plant were prepared with a pre-design of the main equipment. For the capital cost assessment, the factored estimate has been chosen because it considers characteristics of the process: corrosive products, high temperature (up to 850°C for Section II) and high pressure (up to 50 bar for the helium coolant). The factored method is essentially based upon charts and formulas developed over 30 years in the petroleum and chemical industries in France (Chauvel, 2000). It consists of estimating costs of basic equipment (generally carbon steel) and correcting them for materials factors. Exclusively for shell and tube heat exchangers, the Purohit Method has been used (Purohit, 1983). This method takes into account a large number of technical characteristics according to TEMA standard and allows the use of correction factors for different materials. Material factors compared with carbon steel have been updated in 2008 (Gilardi, 2008). The hybrid sulphur process requires electrolysers which are not described in chemical engineering economics literature. A specific approach has been developed by collecting data from literature and constructors of alkaline electrolysers (Mansilla, 2008). Electrolyser characteristics are also considered (catalyst coating, membranes). Once the purchased equipment costs are known, the capital investment can be calculated by summing these results and using ratio factors for installation, piping, buildings, instrumentation, electric equipment, thermal isolation, indirect expenses, etc. (Chauvel, 2000). Economic data of the hybrid sulphur cycle Considering the equipment design for a plant producing 1 kmol/s H 2 , preliminary calculations suggests unreasonable sizing for the plant. Thus, a plant with 7 to 10 manufacturing facilities is proposed (this number requiring optimisation from an economics standpoint). We consider the hydrogen pressure to be 10 bar. Connection with nuclear reactor is not studied therein. Due to the lack of SO 2 electrolysers, alkaline electrolysers are considered as the reference for economic assessment. Electrodes are assumed to be made of carbon steel with a platinum coating. Electrolysis unit requires an investment of EUR(08) 303.8 M with each electrolyser requiring about EUR(08) 2 920/m 2 . Coating and membrane costs sensitivities have been studied (Figure 3) in cases of coating thickness or cost doubling (resp. membrane cost doubling). As a result, the installed electrolysers cost increases up to 20% (resp. 24%). 218 NUCLEAR PRODUCTION OF HYDROGEN – © OECD/NEA 2010
INTEGRATED LABORATORY SCALE DEMONSTRATION EXPERIMENT OF THE HYBRID SULPHUR CYCLE AND PRELIMINARY SCALE-UP Figure 3: Cost sensitivities for electrolysers Relative Difference on Installed Electrolyzers Costs 30% 25% 20% 15% 10% 5% 0% -5% -10% -15% -40% -20% 0% 20% 40% 60% 80% 100% Relative Change of coating thickness and costs (platinum, membrane) Thickness and Cost Pt Membrane Cost Separation SO 2 /O 2 requires two absorption columns. Only one column is shown in Figure 2, the second one finishing SO 2 absorption before exhausting (or valorisation of oxygen which is not taken into account therein). This section also requires heat exchangers and compressors. Cost of installed chemical equipment with piping, instrumentation, buildings, etc. is about EUR 223.8 M. Sulphuric acid concentration, performed in two steps, requires eight heat exchangers, one pump and a knockout drum. A nickel-iron-chromium alloy is used for the majority of equipment and piping due to the presence of hot concentrated sulphuric acid. Capital investment of this section is about EUR(08) 57.3 M (it includes tanks for sulphuric acid). Concentrated sulphur acid evaporation and dehydration is performed in a group of two heat exchangers with important exchange surface (up to 1 340 m 2 ) (HX-208). The SO 3 /SO 2 decomposition reactor (HX-209) is a set of five reactors with two reactive zones. The first one, with a temperature of 875 K requires a platinum catalyst and the second one an iron-oxide catalyst. The operating temperature in the second zone increases up to 1 125 K. Due to operating conditions (temperature, chemical composition), these three devices require a nickel-iron-chromium alloy. Then sulphur trioxide recombination reactor consists of a packed column (HX-210). Required investment for SO 3 conversion is estimated about EUR(08) 508.6 M. Plant starting requires raw materials, in particular sulphuric acid (1 360 tonnes with a price of EUR(08) 1 200 M per tonne). Battery limits investments for the chemical plant is estimated around EUR(08) 1 095 M, including tanks and sulphuric acid. Our results can also be submitted in another manner, i.e. showing respective weights of the different equipment. Four major devices represent 88% of the investment: those for SO 3 conversion (HX-208, 28%, HX-209, 16%), electrolysis unit (28%) and compressors/turbines (16%). Platinum price doubling leads to an increase of 9% of capital investment of the chemical plant due to platinum use in SO 3 /SO 2 conversion reactor and for electrolysers. Except for shell and tube exchangers, purchased costs were estimated by means of charts from the “Chauvel Method” (Chauvel, 2000), then multiplied by correcting factors (materials for example). Other charts have then been used for purchased costs, the second step requiring correcting factors being the same as previously. These different methods show finally various results with a decrease of about 24% of the total capital investment (Peters, 2003; Ulrich, 2004). Operational cost Operational costs include fixed and variable costs per year. The following items have been assessed: maintenance, which is the main contributor, labour and raw materials. Energy costs are not considered in this study. Maintenance is estimated with ratio of capital investment for chemical NUCLEAR PRODUCTION OF HYDROGEN – © OECD/NEA 2010 219
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Nuclear Science 2010 Nuclear Produc
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ORGANISATION FOR ECONOMIC CO-OPERAT
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TABLE OF CONTENTS Table of contents
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TABLE OF CONTENTS Y. Gong, E. Chalk
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EXECUTIVE SUMMARY Executive summary
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EXECUTIVE SUMMARY steam turbine, in
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EXECUTIVE SUMMARY sulphur depositio
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EXECUTIVE SUMMARY affords saving 35
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EXECUTIVE SUMMARY safety assessment
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EXECUTIVE SUMMARY The question was
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CHANGING THE WORLD WITH HYDROGEN AN
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NUCLEAR HYDROGEN PRODUCTION PROGRAM
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NUCLEAR HYDROGEN PRODUCTION PROGRAM
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FRENCH RESEARCH STRATEGY TO USE NUC
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PRESENT STATUS OF HTGR AND HYDROGEN
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STATUS OF THE KOREAN NUCLEAR HYDROG
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THE CONCEPT OF NUCLEAR HYDROGEN PRO
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CANADIAN NUCLEAR HYDROGEN R&D PROGR
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APPLICATION OF NUCLEAR-PRODUCED HYD
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STATUS OF THE INL HIGH-TEMPERATURE
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HIGH-TEMPERATURE STEAM ELECTROLYSIS
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MATERIALS DEVELOPMENT FOR SOEC Mate
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A METALLIC SEAL FOR HIGH-TEMPERATUR
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DEGRADATION MECHANISMS IN SOLID OXI
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CAUSES OF DEGRADATION IN A SOLID OX
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70 μm CAUSES OF DEGRADATION IN A S
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NUCLEAR HYDROGEN USING HIGH TEMPERA
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SESSION III: THERMOCHEMICAL SULPHUR
Page 170 and 171: CEA ASSESSMENT OF THE SULPHUR-IODIN
Page 181: STATUS OF THE INERI SULPHUR-IODINE
Page 184 and 185: INFLUENCE OF HTR CORE INLET AND OUT
Page 194 and 195: EXPERIMENTAL STUDY OF THE VAPOUR-LI
Page 203: DEVELOPMENT OF HI DECOMPOSITION PRO
Page 206 and 207: SOUTH AFRICA’S NUCLEAR HYDROGEN P
Page 216 and 217: INTEGRATED LABORATORY SCALE DEMONST
Page 225: DEVELOPMENT STATUS OF THE HYBRID SU
Page 229 and 230: RECENT CANADIAN ADVANCES IN THE THE
Page 237 and 238: AN OVERVIEW OF R&D ACTIVITIES FOR T
Page 245 and 246: STUDY OF THE HYDROLYSIS REACTION OF
Page 253 and 254: DEVELOPMENT OF CuCl-HCl ELECTROLYSI
Page 259: DEVELOPMENT OF CuCl-HCl ELECTROLYSI
Page 262 and 263: EXERGY ANALYSIS OF THE Cu-Cl CYCLE
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CaBr 2 HYDROLYSIS FOR HBr PRODUCTIO
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SESSION V: ECONOMICS AND MARKET ANA
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DEVELOPMENT OF THE HYDROGEN ECONOMI
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NUCLEAR H 2 PRODUCTION - A UTILITY
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ALKALINE AND HIGH-TEMPERATURE ELECT
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THE PRODUCT OF HYDROGEN BY NUCLEAR
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SUSTAINABLE ELECTRICITY SUPPLY IN T
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PROHYTEC, THE FRENCH INDUSTRIAL PLA
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NHI ECONOMIC ANALYSIS OF CANDIDATE
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MARKET VIABILITY OF NUCLEAR HYDROGE
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POSSIBILITY OF ACTIVE CARBON RECYCL
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NUCLEAR SAFETY AND REGULATORY CONSI
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TRANSIENT MODELLING OF S-I CYCLE TH
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PROPOSED CHEMICAL PLANT INITIATED A
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CONCEPTUAL DESIGN OF THE HTTR-IS NU
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USE OF PSA FOR DESIGN OF EMERGENCY
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HEAT PUMP CYCLE BY HYDROGEN-ABSORBI
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HEAT EXCHANGER TEMPERATURE RESPONSE
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ALTERNATE VHTR/HTE INTERFACE FOR MI
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POSTER SESSION CONTRIBUTIONS Poster
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ACTIVITIES OF NUCLEAR RESEARCH INST
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ACTIVITIES OF NUCLEAR RESEARCH INST
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A URANIUM THERMOCHEMICAL CYCLE FOR
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A URANIUM THERMOCHEMICAL CYCLE FOR
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MEETING ORGANISATION Annex 1: Meeti
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LIST OF PARTICIPANTS REYTIER, Magal
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LIST OF PARTICIPANTS BROWN, Nichola
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LIST OF PARTICIPANTS SINK, Carl US
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