Carbon and Hydrogen
from Natural Gas
– with no CO2-emission
Johan Arnold Johansen
Elkem Carbon AS
Carbon and Hydrogen from NG
Natural Gas
Hydrogen
CH4
C + 2H2
Carbon
Carbon produced from NG
Process flow
Recirculation of unconverted
CH4 C + 2H2
Natural
gas
Preheater
Gas
separation
Main
Reactor
C-product
~99%
Carbon
Purification/
Post proc.
C-product
~99%
H2 for
process heating
C-product
>99.999%
H2 >99.99%
Process flow
Mass/Volume flows – all figures relate to 1000 kg/h of carbon produced
Recirculation of unconverted
Natural
gas
1350 kg/h
1886 Nm3/h
Preheater
Main
Reactor
Carbon
Purification/
Post proc.
C-product
>99.99%
1000 kg/h
Gas
separation
H2 >99.99%
197 kg/h
2350 Nm3/h
H2 for
process heating
130 kg/h
1500 Nm3/h
Process flow
Energy – all figures relate to 1000 kg/h of carbon produced
Recirculation of unconverted
Natural
gas
Preheater
20000 kWh
Gas
separation
Main
Reactor
H2 >99.99%
6700 kWh
H2 for
process heating
• Steam generation
- 4300kg/h
- 5 bar
- 180oC
• Significant amount of
low temperature water
Carbon
Purification/
Post proc.
C-product
>99.99%
1000 kg/h
~4400 kWh
Powered by electricity
~1400 kWh
Industrial us of Carbon
(low Sulphur)
,
FeSi FeMn
Iron and Steel
Aluminium
Steel and Silicon
Aluminium
Nano Carbon
Batteries
Catalyst Support
Activated carbon
Reduction carbon
Anodes
High grade 99,99 C
Composites for wind mills
Power plants
Paint, Concrete, Composites
Electrodes
Cathodes
Recarburizers
Reduction carbon
Energy
Standard grade 98,5 - 99,5% C
New Materials
Electronic
Nano divices
Silicon and
Aluminium
Biotechnology
Medical
applications
Hydrogen
storage
Water Cleaning
Oil and Gas
Energy
Sensors
CNF
Production
(small scale)
CNF
Production
(large scale)
Catalyst
supports
Composite
materials
Electrode
materials
Industrial use of Carbon
ca. 500 kg
Carbon
ca. 1000 kg
Carbon
1000 kg
Aluminium
1000 kg
Silicon for
Solar Cells
Industrial use of Carbon
Aluminium: Moderate sized smelter
Al-production: 300 000 ton Al/year
C-demand: ~150 000 ton/year
Natural gas needed for C-production: 283 million Nm3/year
H2-produced: 29 million kg/year
75 000 cars
20000km/yr with
Fuel cells
Elkem Solar plant in Kristiansand
Si-production: 6000 ton Si/year
C-demand: ~6000 ton/year
Natural gas needed for C-production: 11 million Nm3/year
H2-produced: 1.2 million kg/year
Industrial use of Carbon
• Carbon from the process is a very interesting
alternative to existing Carbon sources
– Petroleum Coke
– Metallurgical Coke
– Coal
• Price is not yet competitive for large scale use
• Cost is very much dependent on future demand
for and use of Hydrogen
Large scale use of Hydrogen
• Lack of technology for large scale use,
distribution and storage of Hydrogen
• Hydrogen can be used in
– Oil refineries
– Extended use of Natural Gas – Gas to Liquids
– Energy
Hyrdogen use in Oil Refining
•Better utilization of old oil fields
•Upgrading of heavy oils
•More environmental friendly use of oil
derivates as fuel in transport
Hydrogen + Naturgass
Hydrogen
Hydrogen used as Gas
Alternatives for use of Hydrogen
•
•
•
•
•
•
•
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Process industry
Metallurgical industry
Fuel in transportation
Electricity production with fuel cells
Electricity production- combustion
Refineries – upgrading of heavy oils
Chemical industry
Synthetic fuel
Future
• We have a process with great potential
– Environmental friendly use of Natural Gas
• We need carbon in the future
– Carbon from the process can be used in existing
market and in most applications
• Large scale demand for Hydrogen is the
biggest challenge
• The process must be part of an integrated
industrial cluster.
Integrated with production of Aluminium
Power plant
CO2 to reservoir
CH4
Natural Gas
445 mill Sm3/y
CH4
3,5TWh
CO
H2
C
350 000t/y
235 000t/y
Al2O3 + 3 C = 2Al + 3 CO
Carbon Production
Carbo thermic production of Al CO
H2
Production of synth gas
Synthetic Fuel (MTO;DME)
Aluminum
Products
Conclusion
• No company in Norway can develop and
establish large industrial clusters
• Large scale industrial use of Natural Gas in
Norway is dependent of political initiatives to
make cooperation between companies
attractive and possible.
for your kind
attention