A research and development program is under way at the Idaho National Laboratory (INL) to assess the technological and scale-up issues associated with the implementation of solid-oxide electrolysis cell technology for efficient high-temperature hydrogen production from steam. This work is supported by the US Department of Energy, Office of Nuclear Energy, under the Nuclear Hydrogen Initiative. This paper will provide an overview of large-scale system modeling results and economic analyses that have been completed to date. System analysis results have been obtained using the commercial code UniSim, augmented with a custom high-temperature electrolyzer module. Economic analysis results were based on the DOE H2A analysis methodology. The process flow diagrams for the system simulations include an advanced nuclear reactor as a source of high-temperature process heat, a power cycle and a coupled steam electrolysis loop. Several reactor types and power cycles have been considered, over a range of reactor outlet temperatures. Pure steam electrolysis for hydrogen production as well as coelectrolysis for syngas production from steam/carbon dioxide mixtures have both been considered. In addition, the feasibility of coupling the high-temperature electrolysis process to biomass and coal-based synthetic fuels production has been considered. These simulations demonstrate that the addition of supplementary nuclear hydrogen to synthetic fuels production from any carbon source minimizes emissions of carbon dioxide during the production process.

The Department of Energy, Office of Nuclear Energy, has requested that a Hydrogen Technology Down-Selection be performed to identify the hydrogen production technology that has the best potential for timely commercial demonstration and for ultimate deployment with the Next Generation Nuclear Plant (NGNP). An Independent Review Team (IRT) has been assembled to execute the down-selection. This report has been prepared to provide the members of the Independent Review Team with detailed background information on the High Temperature Electrolysis (HTE) process, hardware, and state of the art. The Idaho National Laboratory has been serving as the lead lab for HTE research and development under the Nuclear Hydrogen Initiative. The INL HTE program has included small-scale experiments, detailed computational modeling, system modeling, and technology demonstration. Aspects of all of these activities are included in this report. In terms of technology demonstration, the INL successfully completed a 1000-hour test of the HTE Integrated Laboratory Scale (ILS) technology demonstration experiment during the fall of 2008. The HTE ILS achieved a hydrogen production rate in excess of 5.7 Nm 3 /hr, with a power consumption of 18 kW. This hydrogen production rate is far larger than has been demonstrated by any of the thermochemical or hybrid processes to date.This report was prepared in April-May 2009 specifically for the IRT, which at the end of its evaluation in July 2009, recommended that:DOE-NE should focus on the continued development of HTSE [High Temperature Steam Electrolysis] as the leading candidate for integration with NGNP in 2021. This conclusion is based upon the IRT judgment that HTSE has the highest probability of meeting the down-selection criteria described in the report, including efficient production of hydrogen at NGNP conditions.

This report presents results from the development and optimization of a reference commercialscale high-temperature electrolysis (HTE) plant for hydrogen production. The reference plant design is driven by a high-temperature helium-cooled reactor coupled to a direct Brayton power cycle. The reference design reactor power is 600 MWt, with a primary system pressure of 7.0 MPa, and reactor inlet and outlet fluid temperatures of 540° C and 900°C, respectively. The electrolysis unit used to produce hydrogen consists of 4.176 × 10 6 cells with a per-cell active area of 225 cm 2 . A nominal cell area-specific resistance, ASR, value of 0.4 Ohm·cm 2 with a current density of 0.25 A/cm 2 was used, and isothermal boundary conditions were assumed. The optimized design for the reference hydrogen production plant operates at a system pressure of 5.0 MPa, and utilizes an air-sweep system to remove the excess oxygen that is evolved on the anode side of the electrolyzer. The inlet air for the air-sweep system is compressed to the system operating pressure of 5.0 MPa in a four-stage compressor with intercooling. The overall system thermal-to-hydrogen production efficiency (based on the low heating value of the produced hydrogen) is 49.07% at a hydrogen production rate of 2.45 kg/s with the high-temperature helium-cooled reactor concept. The information presented in this report is intended to establish an optimized design for the reference nuclear-driven HTE hydrogen production plant so that parameters can be compared with other hydrogen production methods and power cycles to evaluate relative performance characteristics and plant economics.iii

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