Operational optimization and simulation of Power-to-Ammonia (P2A) - - PowerPoint PPT Presentation

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Operational optimization and simulation of Power-to-Ammonia (P2A) - - PowerPoint PPT Presentation

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VTT TECHNICAL RESEARCH CENTRE OF FINLAND LTD Operational optimization and simulation of Power-to-Ammonia (P2A) process 18.05.17 NH3 Event 2017 Robert Weiss , Jouni Savolainen, Matti Thtinen, Teemu Sihvonen, VTT Technical Research Centre of

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VTT TECHNICAL RESEARCH CENTRE OF FINLAND LTD

Operational optimization and simulation of Power-to-Ammonia (P2A) process

18.05.17 NH3 Event 2017

Robert Weiss, Jouni Savolainen, Matti Tähtinen, Teemu Sihvonen, VTT Technical Research Centre of Finland Ltd., Finland Yasmina Bennani, Vincent Hans, Hans Vrijenhoef, Proton Ventures BV, The Netherlands

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Contents

§ Introduction

§ Nitrogen fertilizer use in Europe § Small scale Power-to-Ammonia

§ Sizing and operation of a Power-to-Ammonia plant

§ Dynamic simulation: Virtual tests of plant dynamics § Robust optimization and market operations: Scheduling, profitability and CO2-emissions reduction in wind power intensive West Denmark.

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Source: European Spatial Monitoring System, 2011 Source: Eurostat, 2016

Nitrogen fertiliser usage in Europe 2005 Installed wind capacity in Europe 2011

Nitrogen fertilizer use in Europe

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Source: European Spatial Monitoring System, 2011 Source: Eurostat, 2016

Nitrogen fertiliser usage in Europe 2005 Installed wind capacity in Europe 2011

Nitrogen fertilizer use in Europe

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Power to ammonia

Small scale ammonia production makes it possible to produce green decentralized ammonia which can be further used as:

  • Nitrogen carrier for fertilizers
  • Hydrogen carrier
  • Energy storage
  • Fuel

Feedstock:

  • Electricity from renewable sources i.e.

wind turbines, PV

  • Air via N2/O2 separation (PSA)

Source: http://www.protonventures.com

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Wind-driven Small-scale Ammonia mill

Wind power capacity

Full load

Nominal Capacity

NH3

Wind power:

  • Intermittency
  • Forecasting errors: Uncertainty, depends on forecast horizon

è Challenge for operational scheduling

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Wind-driven Small-scale Ammonia mill

Wind power capacity PEM Electrolyzer

PEM Overload Capacity

60% /30min

H2

Buffer

Flexible Ammonia process H2

Full load Part load 30-100%

Nominal Capacity

NH3 Market Power

Wind power:

  • Intermittency
  • Forecasting errors: Uncertainty, depends on forecast horizon

è Challenge for operational scheduling

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High-fidelty APROS simulator model

for virtual test of process dynamics and control concepts

www.apros.fi

Apros is a versatile high fidelty first principles dynamic simulator, including § thermal hydraulics networks, § automation & control, and § specialized dynamic models for

§ Power-to-gas electrolysis and § Haber-Bosch synthesis

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Virtual test of power-to-ammonia dynamics: Primary Frequency Control operation in West Denmark (DK1)

In this example test we used an optimal 5-day hourly operation plan for the power-to-ammonia plant:

  • Available wind power (Day-ahead Forecast)
  • Wholesales spot power purchase and sales (Day-ahead hourly)
  • Primary Frequency Control capacity sold (Day-ahead 4-hour

blocks)

  • Running schedule for power-to-ammonia plant units (Day-ahead

hourly)

5 d

www.apros.fi

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Virtual test of power-to-ammonia dynamics: Primary Frequency Control operation in West Denmark (DK1)

Power consumption including executed frequency control

Schedule and TSO system frequency data (0.1-1s resolution) à the actual primary frequency control response of the PEM electrolyser units. à dynamic responses of all subsequent process units, and the plant power consumption.

www.apros.fi

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Virtual test of power-to-ammonia dynamics: Primary Frequency Control operation in West Denmark (DK1)

The operation mode performed well in the virtual tests.

  • Despite fast fluctuating power input, we achieved stable and

good operating conditions (p,T) for NH3 synthesis reactor

  • Some process valve controls had to be updated, especially for

very large and fast transients.

  • Gas storages operation schedules: Daily initial and end-target

storage levels important, some revision on sizes/max pressures

Power consumption including executed frequency control NH3 synthesis reactor

Similar test results for following wind power production.

H2 balance and storage pressure

www.apros.fi

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Small scale ammonia plant

Operation optimization – example cases

§ Case 1: Plant inside the fence of a wind park

§ Subcase G50%: Restricted grid connection to 50% of wind park max capacity

§ Intra-day trade balances WP forecast error except for the final hour-ahead WP forecast § Robust optimization reserves optimal capacity to mitigate worst-case errors in final hour-ahead WP forecast § Assumed automatic load following within execution hour

§ Case 2: Plant in DSO grid, hourly Net Settlement with wind park

§ Subcase PFC: Plant is also able to sell Primary Frequency Control on day-ahead basis.

§ Load following not allowed. § Robust optimization reserves optimal day-ahead capacity to mitigate worst-case distortions for prolonged PFC response.

§ Case 3: P2NH3 plant buying only market power and Certificates of Origin

§ Subcase PFC: like in case 2.

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Example market area – West Denmark DK1 in 2016

We used

  • wind power production data,
  • power spot price data and
  • primary regulation price data
  • f West Denmark, DK1 price and control area

(Energinet.dk 2016; NordPool 2016). Grid fees in the cases ranged between 7.6 to 48.8 EUR/MWh. DK1 spot price

  • 54 to 105 €/MWh
  • average of 26.7 €/MWh

This area is well known for a high intensity of wind power, which during peak production times was up to 200% of the power consumption in the area during 2016. In 2015, 42% of the power used was wind power.

100% : WP prod. = consumption

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Case1: Plant inside the fence of a Wind Park Restricted grid connection to 50% of Wind Park max capacity

12.5 MW Wind park

Hourly power production as in DK1 = same timing as DK1 market wind power

Grid connection only 50% = 6.25 MW

Without storage, 12.5% of the produced wind energy would be stranded

Grid connection capacity

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Case1: Plant inside the fence of a Wind Park Restricted grid connection to 50% of Wind Park max capacity

12.5 MW Wind park

Hourly power production as in DK1 = same timing as DK1 market wind power

Grid connection only 50% = 6.25 MW

Without storage, 12.5% of the produced wind energy would be stranded à This was avoided!

4000 tNH3/year ammonia plant

5 MWe electrolysis (nominal)

  • 4 parallel PEM electrolysers
  • 60% overload capacity

5 hours intermediate H2 buffer Haber-Bosch flexibility 30-100%

Grid connection capacity

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Wind power utilization and CO2 emission reduction

High Wind power utilization was reached for case 1 ”Inside Fence of Wind park” and case 2 ”Net Settlement”. For case 3 ”pure market purchase”, only slighly higher WP than yearly average of grid was reached. PFC operation increased slightly market purchases, decreasing WP share. Case 3 increased the CO2-emissions of NH3 production, since the non-WP share of grid market power purchases contain a high share of fossil based power, especially coal fired power.

Wind power utilization includes here both

  • direct ”own” WP, and
  • indirect grid WP (hourly share of market purchases, via settlement

calculation from DK1 official timeseries)

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Wind power utilization and CO2 emission reduction

High Wind power utilization was reached for case 1 ”Inside Fence of Wind park” and case 2 ”Net Settlement”. For case 3 ”pure market purchase”, only slighly higher WP than yearly average of grid was reached. PFC operation increased slightly market purchases, decreasing WP share. Case 3 increased the CO2-emissions of NH3 production, since the non-WP share of grid market power purchases contain a high share of fossil based power, especially coal fired power.

Wind power utilization includes here both

  • direct ”own” WP, and
  • indirect grid WP (hourly share of market purchases, via settlement

calculation from DK1 official timeseries)

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Wind power utilization and CO2 emission reduction

High Wind power utilization was reached for case 1 ”Inside Fence of Wind park” and case 2 ”Net Settlement”. For case 3 ”pure market purchase”, only slighly higher WP than yearly average of grid was reached. PFC operation increased slightly market purchases, decreasing WP share. Case 3 increased the CO2-emissions of NH3 production, since the non-WP share of grid market power purchases contain a high share of fossil based power, especially coal fired power.

Wind power utilization includes here both

  • direct ”own” WP, and
  • indirect grid WP (hourly share of market purchases, via settlement

calculation from DK1 official timeseries)

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Wind power utilization and CO2 emission reduction

High Wind power utilization was reached for case 1 ”Inside Fence of Wind park” and case 2 ”Net Settlement”. For case 3 ”pure market purchase”, only slighly higher WP than yearly average of grid was reached. PFC operation increased slightly market purchases, decreasing WP share. Case 3 increased the CO2-emissions of NH3 production, since the non-WP share of grid market power purchases contain a high share of fossil based power, especially coal fired power.

Wind power utilization includes here both

  • direct ”own” WP, and
  • indirect grid WP (hourly share of market purchases, via settlement

calculation from DK1 official timeseries)

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Production Costs

Strongly dependent on operation case Primary Frequency control: § Good income potential § Assymmetric Bidding in DK1 area is beneficial for electrolysers! Compare to global market price range

  • f 250-700 EUR /tNH3

for conventional fossil NH3 during 2010-2016

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Production Costs

Strongly dependent on operation case Primary Frequency control: § Good income potential § Assymmetric Bidding in DK1 area is beneficial for electrolysers! Some additional income potential from O2 sales (estimate 50-70 EUR/tNH3) CAPEX share still very large

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Ammonia total production cost:

Impact of CAPEX and Wind Power cost

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Summary and conclusions

§ Small Scale Power-to-ammonia example was shown for Danish wind power and market (DK1) conditions. § Operational planning needed to find economical case and CO2-reduction potential.

§ ”Net settlement with wind power” or ”Inside fence of Wind park” operation seems to be suitable in Denmark, while a pure market-based operation has clear drawbacks.

§ Process dynamics provides needed flexibility to meet intermittency of wind power.

§ PEM electrolyzer’s capacity to temporarily overload is beneficial.

§ Participation to electrical grid ancillary services is essential.

§ DK1 assymetric bidding is beneficial for PtX.

§ Robust optimization was needed in the operational planning to include the effects of uncertainty for Primary Frequency control and mitigation of Wind Power forecast errors. § Competitive or at least acceptable NH3-prices seem to be reachable within near future.

§ Would economy of scale help in P2A?