1 BIONICO B IOGAS MEMBRANE REFORMER FOR DECENTRALIZED H 2 PRODUCTION Call: H2020-JTI-FCH-2014-1 Topic: FCH-02.2-2014 Decentralized hydrogen production from clean CO 2 -containing biogas 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
2 S UMMARY BIONICO aims at developing a novel reactor configuration at a larger scale to produce H 2 from biogas production power plant based on: Design, develop and test a new concept reactor integrating hydrogen production and purification on a single unit Design, develop and testing of a catalytic membrane reactor for the production of highly-purity hydrogen from biogas, scaling up new H 2 selective membranes and catalyst production Develop a flexible system (including the advance control and BoP components) capable of producing pure hydrogen from biogas of different composition s in a unique reactor system. The main idea of BIONICO is to design and demonstrate an efficient biogas-to-hydrogen conversion system at real plant conditions using process intensification. 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
3 C ONCEPT 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
4 W HY B IONICO ? h Offgas 0.52 C ONVENTIONAL S YSTEM REFORMER PSA HT-WGS LT-WGS SR / ATR ( H 2 Purification ) (350°C) (200°C) (800°C) HYDROGEN Sulphur BIOGAS PLANT Removal M EMBRANE R EACTOR (500-600°C) Retentate h >0.70 Reference Case Results units SR ATR Two reference cases (based on SR and Biogas feed Nm 3 /h 39.5 63.5 Total Biogas Input kW 229 368 ATR) are identified to benchmark the System efficiency % LHV 51.7 27.8 performance of the BIONICO concept Hydrogen delivery bar 20 20 pressure Hydrogen € /kg 4.21 6.37 production cost The target of BIONICO is a system efficiency above 70% LHV , which is about 25% higher than SR (52% LHV ). The higher efficiency together with equipment savings will end up in lower hydrogen production costs. 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
5 P ARTNERSHIP Multidisciplinary and complementary team: 8 top level European organisations from 7 countries including 3 Research Institutes and Universities and 4 representative top industries in different sectors (from catalyst to membranes to chemical and process engineering, etc.) POLIMI, Italy TU/e, The Netherlands Abengoa, Spain Tecnalia, Spain ICI caldaie, Italy Johnson Matthey, UK ENC Energy, Portugal Rauschert, Germany Quantis, Switzerland 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
6 W ORK STRUCTURE 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
7 P ARTNERSHIP S YNERGIES ICI ICI ICI ICI ICI 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
8 N OVEL C ATALYST G OAL Development of highly active reforming catalysts to produce hydrogen from diverse biogas mixture coupled with steam and air in a fluidised bed regime. T HREE Y EARS P ROJECT A CTIVITIES PGM doped alumina catalysts have been tested under biogas reforming conditions for dry, steam or autothermal reforming Coke formation resistance improvement A CHIEVEMENTS 1 st generation catalyst and 2 nd generation catalyst able to work under fluidisation regime and at low temperature Final Catalyst formula produced and shipped to ICI 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
9 N OVEL M EMBRANE & S UPPORT G OAL Development of Pd based tubular supported membranes, for application in biogas reforming catalytic membrane reactors T HREE Y EARS P ROJECT A CTIVITIES Preparation of porous ceramic tubes of different diameters and materials for their use as supports for thin Pd-based membranes Manufacturing of thin film (<5 µm thick) Pd-Ag and Pd-Ag-Au membranes on top of the ceramic supports. Development of new finger-like porous asymmetric ceramic supports in which one of the ends of the tube is a closed porous part. Finger-like asymmetric porous ceramic supports 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
10 N OVEL M EMBRANE & S UPPORT G OAL Development of Pd based tubular supported membranes, for application in biogas reforming catalytic membrane reactors A CHIEVEMENTS 1 st generation membrane & support Installation of a new plating system for preparation of >40 cm long membranes. 2 nd generation membrane & support. Thin Pd-Ag layers have been deposited onto 2 nd generation thin film Pd-alloy supported the 50 cm long finger-like supports. membranes (>40 cm long) Definition of criteria for support quality Improvement of manufacturing procedure for membrane prototype production Membranes for prototype preparation 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
11 L AB S CALE R EACTOR G OAL Definition of the lab scale reactors performances and identification of the best design for prototype pilot. T HREE Y EARS A CTIVITIES Selection and characterization of the membrane for the prototype Study of long-term membrane performance in a fluidized bed; The effect of H 2 S on the performance of PdAg and PdAgAu membranes are studied Obtain a comprehensive description of the catalyst reaction kinetics Design and demonstration of biogas steam reformer at Lab-scale Development of phenomenological model of the fluidized-bed membrane reactor 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
12 L AB S CALE R EACTOR G OAL Definition of the lab scale reactors performances and identification of the best design for prototype pilot. A CHIEVEMENTS Integration of catalyst and membrane One dimensional phenomenological model of the reactor Effect of Au addition on H 2 S resistance of the membrane 1 E505 PdAg 0.9 Perm H2S /Perm 0 (-) E505 PdAgAu (5%au) 0.8 Model E506 PdAgAu (7%au) 0.7 0.6 0.5 0.4 0.3 0 10 20 H 2 S [ppm] 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
13 L AB S CALE R EACTOR G OAL Definition of the lab scale reactors performances and identification of the best design for prototype pilot. A CHIEVEMENTS Successful description of concentration polarization in the reactor model Lab scale system with 5 membranes equal to the once that will be used in the pilot, as well as the catalyst, have been tested 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
14 P ROTOTYPE R EACTOR G OAL Final design and construction of MR prototype for the production of approximately 100 kg/day of pure hydrogen T HREE Y EARS P ROJECT A CTIVITIES Preliminary design of the prototype catalytic membrane reactor at large scale including control system design Preliminary design of the balance of plant 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
15 P ROTOTYPE R EACTOR G OAL Final design and construction of MR prototype for the production of approximately 100 kg/day of pure hydrogen A CHIEVEMENTS Retentate PURE ATR-MR HYDROGEN A techno-economic optimization of BIONICO H 2 Vacuum Pump HX-4 system was assessed HX-2 Air+H 2 O CMP BG Different operating conditions (T, p, S/C), Air brn BIOGAS biogas compositions and permeate side Exhaust Burner Sep configuration were investigated HX-1 HX-0 Sep Membrane reformer designed and water rec. Air ATR manufactured by ICI H 2 O CMP Air H 2 O feed P-1 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
16 I NTEGRATION &T ESTING AT B IOGAS P RODUCTION S ITE G OAL Final evaluation of the innovative process to directly produce pure hydrogen in a real biogas production site (ENC Landfill plant) T HREE Y EARS P ROJECT A CTIVITIES Definitions of input needed for starting the plant licensing procedure Evaluating the integration of the prototype reactor in the overall BIONICO system at biogas production site Landfill plant Biogas cleaning unit 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
17 L IFE C YCLE A SSESSMENT & S AFETY I SSUES G OAL Development strategy towards sustainable solutions and provide guidance on how to operate the reactor prototype under safe conditions. T HREE Y EARS P ROJECT A CTIVITIES Refined goal & scope of LCA analysis, in particularly, with further clarifications with regard to: (i) reference systems (baseline), i.e., SMR and ATR, (ii) level of details of inventory modeling and (iii) system boundaries Improved data collection for key data points, especially related to functional unit, biogas input, conversion efficiency, energy and water use as well as direct GHG emissions during conversion processes Final LCA analysis between BIONICO CMR and reference technologies In progress of developing applicable safety protocol 24/09/2018 Disclosure or reproduction without prior permission of BIONICO is prohibited
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