Systems and Closed-Loop Manufacturing Systems ASME Energy - - PowerPoint PPT Presentation

Synergistic Integration of Energy Systems and Closed-Loop Manufacturing Systems

• Dr. Benjamin J. Cross, PE

Stephanie Howe Michael Zimmer

ASME Energy Sustainability Conference

Present ntatio ion: n: PowerEne rEnergy gy2018-7611

June e 27, 2018

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PORTSFUTURE

OHIO UNIVERSITY VOINOVICH SCHOOL OF LEADERSHIP AND PUBLIC AFFAIRS DOE EDUCATIONAL ASSISTANCE GRANT

PUBLIC OUTREACH AND APPLIED-ENVIRONMENTAL TASKS FOR THE FORMER PORTSMOUTH GASEOUS DIFFUSION PLANT (PORTS) IN PIKETON, OHIO AND SURROUNDING COUNTIES

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Outline

• Premise for Integration
• Integrated Energy System (IES)
• Closed-Loop Manufacturing (CLM)
• Process Heat Applications & Usage
• PORTS IES-CLM Complex Concept
• IES-CLM Potential Benefits
• IES-CLM Challenges
• Summary/Conclusions

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Premise Premise for Integration for Integration

Systems/processes optimized to work together addresses the Nexus of Energy, Water, Climate, Food, and Waste

• The “whole” is worth more than some of the “parts”

– Synergy obtained from a “systems of systems” approach

• “Smart Systems” can create “Smart Solutions”
• “Value” as a driver—not absolute “cost”

– Value Propositions:

• High Efficiency (i.e., Thermal, Economic)
• High Reliability and Resiliency
• Sustainability
• Minimal water usage
• Low Emissions/Waste Minimization
• Acceptable/Low Cost

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Inte Integrate grated Energy Syste d Energy System

• Technical definition: Two or more energy

resources are utilized as inputs to two or more physically coupled subsystems to produce one or more energy commodities as outputs

• Simpler definition: Multiple energy resources

combined together to produce one or more energy related products

• IES is not a technology, but integrated approach

to applying technologies, “systems of systems”

• Co-locating, combining, interconnecting and/or

networking of energy producers and energy users

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IES IES by Diff y Different erent Name Names

• Cogeneration (Traditional among technical people)

– Usually thought of as a single energy resource producing two energy commodities

• Combined Heat and Power (CHP)

– Natural Gas/Coal/Oil/Biomass to produce steam (process heat) for a chemical process and additionally generate electricity

• Hybrid Energy Systems
• Combined Energy Systems
• Polygeneration

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Coal chemical recycling economy demonstration park in Wuzhong City in Ningxia Providence

China & Polygeneration

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Closed Closed-Loop Loop Man Manuf ufactur acturing ing

(In (Industr dustrial ial Symb Symbiosi iosis) s)

Typical industrial process used today

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Process Heat Applications

Utilize process heat at every temperature level

Hydrogen Production by Water Splitting, Coal Gasification

Hydrogen Production by Steam Methane Reforming Ethanol Concentration Water Purifications

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, PORTS

(~1200 acres)

High Temperature, Hazard, Security, & Investment

(Electricity, Hydrogen, Ammonia Production, Refinery, Metal Extraction &Treatment )

Specialty Chemicals Bulk Chemicals Biomass Drying Water Purification Anaerobic Digestion Enzymatic/Fermentation Grow/Green Houses Algae Farms Polymers/ Resins Plastics Methanol Food Processing Pharmaceuticals Solvents Cleaning Agents Waste Water Treatment Cosmetics Facility Heating District Heating Adhesives Low Temp High Temp Fish Farm & Hatcheries Pulp & Paper Processing

Process H Process Heat eat Usa Usage

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Closed Closed-Lo Loop

• p Coo

Cooling ling Wat ater er

Refinery CCGT Fish Hatchery Grow Houses Green Houses Water Treatment Algae Ponds Anaerobic Digesters

Natural Gas (NG) Municipal Solid Waste (MSW) Biomass (e.g., wood chips, Ag energy grasses/crops) Nuclear Fuel (NF)

(Future)

Heat Sources

High Temperature Process Heat (e.g., Steam)

Electricity Generation Hydrogen Production Natural Gas (NG) Power Grid Hydrogen (H2) Carbon Dioxide (CO2) Refinery Oil Coal MSW Tires Biomass Ammonia Production AIR Ammonia NH3 Methanol Production Carbon Monoxide Hydrocarbons & Alcohols H2 Users

(e.g., Fuel Cells)

Methanol CH3OH Hydro- genation Vegetable Oils Solid or semi-solid fats (Margarine, Shortening) CO2 Users

(e.g.Enhanced Oil Recovery)

Refrigeration & Liquifer Liquid & Solid CO2 Baking and food processing Transportation fuels, heating fuels, bulk & specialty chemicals, pharmaceuticals, industrial solvents, polymers, resins & plastics Fertilizers, metals extraction & treating, plastics, cleaning agents, industrial refrigeration, food processing, emissions control, waste water treatment Fuels, antifreeze, polymers, plastics, resins, solvents, adhesives, waste water treatment Cleaning solvents, beverages, food processing, refrig- eration, pharma- ceuticals, cosmetics Heat Users

IES IES-CLM CLM Complex Complex Conce Concept pt

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Renewables (Solar/Wind)

Gas Turbine NG AIR Duct Burner Electricity Generator NG Exhaust Gas (CO2, H2O, NOX) Steam Turbine Electricity Generator Heat Recovery Steam Generator Steam HRSG Exhaust Gas Recovery Condenser AIR 6 7 Coolant H2O

Initial Initial Phase of IES Phase of IES-CLM CLM

Syngas(CO) Fluidized Bed Boiler NG MSW Biomass AIR Solid Residue Make-up Water Water Treatment Deaerator & Feedwater Heater Demineralized Water Steam Methane Reformer (Un-fired) NG H2 CO2 Condensate Return Exhaust Gas (CO2, H2O, NOX) Economizer (Pre-heater) 1 5 2 3 8 8 10 Steam CO (Syngas) 4 4 9

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2 Refinery

(Hydrodealkylation, hydrodesulfurization, hydrocracking, hydrogenating, etc.)

Oil Coal MSW Tires Biomass Hydrocarbons & Alcohols Char Haber- Bosch Process Urea(carbamide) (Fertilizer) (NH2)2CO AIR (N2) H2 Ammonia (NH3) Urea Synthesis & Granulation CO2 3 Eurotecnica process 1 Steam CO2 NH3 Melamine Synthesis Polymers Resins Numerous industrial & consumer products Methanol CH3OH Formox Process Methanal (Formaldehyde) CH2O 11 11 Methanol Synthesis 4 CO (Syngas) H2 H2 H2 CO2 CO2 H2O 5 O2 Sulfur 12 13 14 Extracted chemicals 15 16 17 Melamine C3N6H6 18 19 20 2 1 3 Catalytic Hydro- genation H2 Vegetable Oils 21 Solid or semi- solid fats (Margarine, Shortening) Food Industry 22 Baked Goods & Processed Foods

Ad Additional ditional Phases of IES Phases of IES-CLM CLM

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IE IES-CLM P CLM Pote

• tential

ntial Benef Benefits its

• Effective resource management (Cost Savings)

– Higher overall efficiency – Recycling of water and materials, including CO2 – Better utilization of capital equipment and lower

• perating expenses
• Shared resources (e.g. infrastructure, facilities, personnel)
• Shared processes (e.g. common/support systems)
• Use of local domestic and renewable resources
• Reduced waste and emissions
• Promotes sustainability on an industrial scale
• Industry collaboration and co-location
• Transformation of brownfield sites

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Challenges

• Multiple organizations working together (Planning)

 Must integrate people before you can integrate systems

• Large Capital Investment ($B’s)
• Security (investment protection)

 Potential terrorist target

• Requires unique sites (Megasites)

 Near energy and other natural resources  Intensive industrial and support infrastructure

• Flexibility and resiliency

 Dependent and independent operations

• Phased development and incorporation of new

technology

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Summary

• IES-CLM is not a new concept or technology

but an integrated approach for applying technologies

 “Systems of Systems” approach focused on comprehensive synergistic integration

• IES-CLM provides opportunity to optimize

efficiency and effective resource management

 Minimize cost and impact on the environment

• IES-CLM addresses the nexus of energy, water,

climate, food, and waste on an industrial scale

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For more information on the project, visit www.portsfuture.com

The PORTSfuture project is funded by a grant from the U.S. Department of Energy Office of Environmental Management Portsmouth/Paducah Project Office

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