Development of a Thermally and Electrically Self-Sustaining Hydrogen Generation System Directly Using Petcoke

Hydrogen has been widely used by petroleum refineries in upgrading processes necessary to facilitate the hydrotreating/catalytic hydrocracking of heavy hydrocarbon molecules and the reduction of sulfur content. However, the building of the infrastructure needed to transport hydrogen from central production facilities to small refineries is cost prohibitive. This project will develop an advanced, thermally and electrically self-sustaining, electrochemical hydrogen generation system for small petroleum refineries applications. In Phase I, electrode materials were identified and deposited using different approaches, an electrochemical device was successfully developed and fabricated, and proof-of-concept tests were performed. Both hydrogen production and power generation, directly using petcoke, was demonstrated. Phase II will focus on improvements and scaling of the hydrogen production technology. Over 500 hours of long-term tests will be performed to investigate possible degradation mechanisms, and the hydrogen production process will be demonstrated at bench-top scale. Commercial Applications and other Benefits as described by the awardee: The technology should enable refineries to convert a locally available inexpensive feedstock, petroleum coke, into hydrogen at a cost much lower than the cost of purchasing hydrogen from a central production facility. Other benefits would include (1) no need for fuel clean-up or secondary purification of the hydrogen product; (2) versatile operations for hydrogen/power generation; (3) a sequestration-ready CO2 production; and (4) a marketable by-product.