Demonstration of Technology Options for Storage of Renewable Energy - - PowerPoint PPT Presentation

Demonstration of Technology Options for Storage of Renewable Energy

• S. Elangovan, J. Hartvigsen, and L. Frost

Ceramatec, Inc. Brainstorming Workshop Institute for Advanced Sustainability Studies e.V. (IASS) Postdam, Germany November 19-20, 2013 Acknowledgement: DOE, ONR, State of WY

Outline

• Introduction
• Technology Needs and Challenges
• Technology Options Pursued at

Ceramatec

– Electrochemical (Solid Oxide) Technology – Fuel Reformation

• Liquid Fuel Synthesis
• Summary

Energy Need Population/ Standard of Living Emissions Global Warming Renewable Energy Geo- Political Energy Storage Petroleum Need

Global Challenges

Energy Need Population/ Standard of Living Emissions Global Warming Renewable Energy Geo- Political Storage Petroleum Need

Where can we apply integrated solution

Increase in Standard of Living & Energy Demand

Shell International, Energy Needs, Choices and Possibilities, Scenarios to 2050, London, 2010

Energy

• Sources

– Oil – Biomass – Gas – Coal – Nuclear – Renewable

• Forms

– Electricity – Heat – Motive Power

• Challenges

– Supply/ Demand – Conversion – Tranportation – Storage – Efficiency – Emission

Ceramatec’s Focus Areas

Renewable Energy

• Abundant
• Location

Constraint Electrochemical

• High Efficiency
• Technology

Maturity?

• Scale up & Cost?

Synthesis Gas

• Source of

Heat, Electricity, Chemicals

Liquid Hydrocarbon

• High

Energy Density

Consumes CO2 Alternative to Sequestration Transportability High Demand

Focus/Interest/Experience

• Electrochemical

ü Solid Oxide Fuel Cell/Solid Oxide Electrolyzer – Molten Salt Electrolyzer (potential scale up option)

• Syngas Generation

ü Co-electrolysis of CO2 and H2O ü Reformation of methane containing gases

• Stranded natural gas
• Biogas
• Landfill gas
• Syngas to Liquid Fuels

ü Fischer Tropsch

Electrochemical Conversion

• Solid Oxide Fuel Cells

– Decades of R&D worldwide – Excellent Technical Progress – Numerous small and large demonstrations – Market introduction?? – How can we benefit from the progress made

• Build on progress
• Expand Applications

• Leverage decades of SOFC R&D
• Inputs

– e- (green electrons) – steam => hydrogen – co-electrolysis of H2O + CO2 => syngas – heat input optional, depends on operating point

• Most efficiency means of hydrogen production

– e- to hydrogen

• η=100% at 1.285V
• η= 95% at 1.35V
• η=107% at 1.20V, (heat required)
• Hot O2 and steam byproducts

– Valuable for biomass gasification

Electrolysis Is The Key To Synfuels

Synfuel Power Market Much Larger Than Grid

Electrolysis at 1.285 V/cell $25/MW-hr Syngas cost $80/bbl

Annual US Electrical Energy Demand GW-hr Petroleum equivalent k-bbl Synfuel electric energy as ratio to current demand Conventional Electric Load 4,119,388

47% of Capacity

1,801,874 1x 470 GW US Crude Oil Imports 3,580,694 2x 940 GW US Crude & Refined Imports 4,726,994

$720k/min @ $80/bbl

2.6x 1,220 GW US Crude Oil Refinery Inputs 5,361,287 3.0x 1,410 GW US Crude & Refined Refinery Inputs 6,277,893 3.5x 1,650 GW

http://tonto.eia.doe.gov/dnav/pet/pet_sum_snd_d_nus_mbbl_a_cur.htm http://www.eia.doe.gov/cneaf/electricity/epa/epates.html

Grid stability restricts wind to ~ 1/6 of load and requires costly reserve

Liquid Hydrocarbon Energy Density and Value

• Energy Density

– Diesel 42 MJ/kg, 0.86 kg/liter – Hydrogen at 690 bar (10,000 psi) Z=1.43

– 4.4 MJ/liter (min. work of compression is 10-12% of LHV)

• Established markets for liquid fuels

– Highly developed infrastructure – Existing vehicle fleet – US demand, 6.3 billion bbl/yr, > $500 billion/yr

• Liquid fuels command a premium

– Negative value for CO2 to $ 85/ton of C for crude oil

Electrochemical Technologies

Renewable Energy + Carbon dioxide Recycle at ~ 100% Efficiency à Synthesis Gas

One Technology - Multiple Modes Of Operation

Fuel

Solid Oxide Stack Module

Electricity Steam + Electricity Hydrogen

(High Purity)

CO2 & Steam + Electricity

Syngas (CO + H2

NG Biogas Diesel JP-8 Coal

Co-electrolysis Reaction Paths

H2O + 2e- → H2 + O2- (electrolysis of steam) kinetics favored [1] CO2 + 2e- → CO + O2- (electrolysis of CO2) kinetics slower [2] CO2 + H2 ↔ CO + H2O (reverse water gas shift ) kinetics fast [3] Reverse shift reaction: CO2 + ⇑ H2 <==> CO + ⇓ H2O As steam is consumed and H2 produced, the RWGSR converts CO2 to CO

[1] [2] [3] [1]

Scale up & Demonstration

• 18 kW Steam Electrolyzer (Ceramatec

Stacks tested at Idaho National Labs.)

720 Cell System Hydrogen Production: 5.7 Nm3/hr

Technical Challenges

• Air electrode delamination
• Chromium poisoning
• Seal challenge (back pressure from

product collection)

• High steam corrosion of metal

interconnect

Electrolysis Stack Stability Progress

Recent ¡SOEC ¡Stacks ¡Meet ¡Life2me ¡Targets ¡

19 ¡

ASR ¡Limit ¡for ¡ 40,000 ¡hr ¡ life2me ¡target ¡ Steam ¡supply ¡ failure ¡

Molten Salt Electrolysis

• Demonstrated at Weizmann Inst., Israel (5000 A cell)
• Operating Principle & Efficiency – same as SOEC
• Near term scale up possible

2 2

CO in O out anode cathode CO out

• 2
• 2

3

2O CO 2 CO + → +

−

e

• 2

3

• 2

2

CO O CO → +

3 2CO

Li

• f

melt

2

• 2

O 2 1 2 O → −

−

e

Cell voltage: 1.05±0.05V Current density: 100 mA/cm2 No Degradation in 700hr test Thermal neutral voltage: 1.46V/cell Faradaic efficiency: 100 % Thermodynamic efficiency: 100%

Reformation Process for Syngas Generation

Stranded Natural Gas Biogas (Anaerobic Digester) Landfill Gas

Reformation

• Low Power Plasma

– Plasma is a continuously renewing catalyst – Low Electric Power Consumption

• ~ 1 to 2% of heating value of fuel
• < 8% heat of reformation

– Sulfur tolerant

Plasma Head

Low Power Plasma: Liquid/Gas Fuel Reformation

• 1
• Large reformer

– Can process 100 thousand standard cubic feet/day of Natural Gas (~3000 m3/ day) – > 1 MWthermal – Can reform liquid fuels – Sulfur tolerant

Reformer scale-up

10 TPD Biomass Gasification Reformer + Gasifier

* Large reformer * To reform residual tars/oil from 10 TPD biomass gasifier

Synfuels Historical Perspective

• Fischer-Tropsch Synthesis

– First commercial plant in Germany, 1936 – Continuous commercial operation in South Africa since 1955

• Secunda plant is CTL
• Also operate GTL

– Shell GTL in Malaysia – Newer plant in Qatar (Oryx)

– Primarily large scale CTL & GTL

• Syngas production cost ~5/6 of total
• Syngas conversion cost ~1/6 of total

– $80 to $120/bbl (depends on electric rate, tax credit)

Challenge: Produce a small scale plant at same cost per bpd capacity as large plant

Ceramatec Laboratory Syngas Facility

Two stage oil free syngas compressor with syngas drying system. Discharge pressure 150-200 psig Inter-stage tank 240 gallon Two 500 gallon, 800 psig syngas tanks; 7200 SCF capacity Final stage oil free compressor. Discharge pressure 800 psig

Ceramatec Laboratory FT System

Capacity: ¡3 ¡to ¡4 ¡liters/day ¡

¡ Single ¡tube ¡FT ¡reactor ¡ 42.7mm ¡ID, ¡2.0 ¡m ¡length, ¡~2.9 ¡liters ¡ ¡ Backpressure ¡regulaHon ¡system, ¡20-­‑30 ¡barg ¡ ¡ High ¡pressure ¡mass ¡flow ¡controllers ¡ ¡ (low/high ¡range) ¡ ¡ Temperature ¡controllers ¡for ¡reactor ¡and ¡ ¡ collecHon ¡system ¡ ¡ Hot ¡and ¡cold ¡product ¡collecHon ¡vessels ¡ ¡ Recycle ¡pump ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡& ¡ Cooling ¡system ¡

Ceramatec FT Product From 1-1/2” Reactor

• Production rates up to 4 liter/day
• 2200 hour run
• FT 46.5 MJ/kg, diesel 46 MJ/kg, 40 MJ/kg B100 FAME
• Cetane 60.2 by ASTM D613

Compressor Scale up

• Capacity equivalent to 2 bpd of FT liquid

Pre-pilot Plant Scale up

4” Reactor Tube - Fischer Tropsch Skid Capacity: 0.25 bpd (40 liters/day)

Novel Design Features

• Major FT Challenge

– Heat removal from exothermic process – Necessitates use of small reactor tubes

• Ceramatec Approach

– Dual cooling loop – Internal heat transfer – Allows the use of larger tubes – 100 mm diameter reactor tested – Allows capital cost reduction

FT Demonstration

30 liters/day FT Production Demonstrated

FT Product Analysis

33 5 10 15 20

5 10 15 20 25 30 35 %CN Carbon Number

081913 090613 091013 091613 091813 091213 091313 100113 100313 100213 093013 092613 092513 092413 092313 092013

30 days of continuous operation showed stable performance

Pilot Plant Layout (10 bpd ~ 1,600 liters/day)

100 bpd preliminary reactor concept developed

The Electrolytic Synfuel Solution

• Electrolysis efficiency – 100% in practice
• Process negates RE shortcomings

– Intermittency – Stranded due to limited transmission reach & capacity

• Efficient, concentrated, RE storage technology

– 36 MJ/liter – 21-26 MW-days storage in a 10,000 gallon tank trailer

• Utilize all carbon content in BTL, CTL, & CC sys
• FT needs 20 bar comp. vs. 700 bar H2 FCV
• Product compatible with existing dist. & vehicles

– 20 to 50 years to retire existing fleet

FT Process

• Syngas from other methane sources can

be used

– Biomass based

• Design options for capital cost reduction
• Operating strategies for cost reduction

Thank You