SOFCOM Mid Term Review

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Emory Byrd
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1 SOFCOM Mid Term Review 1 Status, progress and next steps of WP6 D E S I G N, D E V E L O P M E N T A N D T E S T O F T H E P R O O F - OF- C O N C E P T P L A N T 1 ( I T A L Y : 2 k W CHP, W W T U B I O G A S ) SOFCOM WP6

2 Key objectives of the DEMO in Torino (IT) The main general objective of SOFCOM DEMO unit in Torino (IT) is to demonstrate the high interest of electrochemical systems based on high temperature fuel cells to operate as the core of future energy systems with renewable fuels and multi-product configuration, featuring also a CO2 recovery through re-utilization of the C and H atoms inside the system using different processes (electrochemical, chemical, biological as in SOFCOM). DEMO 1 Torino (IT): field demonstration of WWTU biogas-fed SOFC with CO2 recovery and reuse; real operating environment. The first proof-of-concept SOFC system is able to operate with biogas produced in an industrial waste water treatment unit (WWTU). The plant will be in operation as CHP plant, with heat recovery from the exhaust for the production of hot services (hot water). Also, the plant will be completed with a with a section of CO2 recovery for Carbon reutilization in a photo-bio-reactor for C storage in form of algae (CO2 sink). 2

3 DEMO: WWTU-SOFC-CO2 recovery: overall structure of the DEMO Two CLEANING VESSELS: H 2 S removal => ZnO Siloxanes removal => Activared Carbon 14 SLPM biogas FUEL PROCESSING UNIT Steam reforming (demi water from demineralizer) Evaporator Mixer Reformer (S/C = 2) Reformer Temp. = 750 C SOFC Stack 2 kwe 90 cells, 3YSZ SOFC Temp = 800 C. Inlet fuel Temp = 750 C. Inlet air Temp = 650 C. BIOGAS from SMAT digesters fed by secondary treatment sludges of the WWTP. Biogas: 60% CH 4 40% CO 2 POWER HEAT HEAT ALGAE AIR PRE-HEATER Inlet air pre-heated through a mixed exhaust recuperator/electrical heater. Cathode exhaust used for CHP (water heating). WASTE WATER TREATMENT VIA ALGAE GROWTH 3 PBR modules (9 m 2 ) Algae production 8 g dry /h Outlet streams: Treated water (reduced N/P compounds) Algae (to digesters) CO 2 SEPARATION UNIT Water condenser Compressor up to 5 bar Pressurized membrane stage => H 2 O < 500 ppm 3

4 DEMO: WWTU-SOFC-CO2 recovery: GANTT N TASK ,1 Biogas production 6,2 Biogas cleaning system 6,3 Biogas processing system 6,4 SOFC CCHP system O2 separation and anode 6,5 exhaust catalytic burner 6,6 6,7 CO2 separation from anode exhaust CO2 management and disposal system 6,8 Testing of the complete system Monitoring of the complete 6,9 system in the long run YEAR 2 YEAR 3 4

12 «Detailed blueprint of the demonstration of integrated system WWTU

5 PREVIOUS WORK UP TO M24 July 2013 Detailed design of the demonstration plant. August 2013 Deliverable 6.12 «Detailed blueprint of the demonstration of integrated system WWTU biogas + SOFC in Torino October 2013 SMAT: assignment of the installation and material/accessories supply to an external company 5

6 PLANT AREA (I) SMAT WWTU Plant, Torino (IT): serves over 2 million population equivalents in the metropolitan area of Torino treating over cubic meters per day of waste water, with a production of Nm 3 /day biogas 6

7 PLANT AREA (II) Instrument air Waste water Biogas Tap water Service water Drain 7

8 PLANT AREA (III) Demonstration plant Shed Hydrogen Oxygen Nitrogen Control Room Carbon Dioxide Photobioreactor 8

9 DEMONSTRATION PLANT 9

10 SOFCOM Demo Plant Units Cleaning Unit Reforming Unit SOFC Stack Unit Oxy-combustor CO2 separation Unit Algae Water Treatment 10

11 CLEANING UNIT (I) Inlet biogas from SMAT max. 14 SLPM 100 ppm H2S 1100 ppb siloxanes N2 for bed substitution 2 SLPM/month CLEANING VESSELS Clean biogas to the reformer 11

12 CLEANING UNIT (II) H 2 S adsorber Outside diameter 88 mm Inside diameter 85 mm Height 1. ZnO: 30 cm 2. SiC: 5 cm 3. ZnO: 30 cm Particle size ZnO: 4.5 mm SiC: 1.3 mm Clariant catalyst ActiSorb S2 (G-72 D) Siloxane adsorber Outside diameter 88 mm Inside diameter 85 mm Height 1. AC: 30 cm 2. SiC: 5 cm 3. AC: 30 cm Particle size: AC: 4.5 mm SiC: 1.3 mm Norit RST3, steam activated carbn 12

13 SOFCOM Demo Plant Units Cleaning Unit Fuel Processing SOFC Stack Unit Oxy-combustor CO2 separation Unit Algae Water Treatment 13

14 FUEL PROCESSING (I) Biogas from cleaning H2 for stand-by To Reformer VENTING N2 for start-up and stand-by To SOFC REFORMER Demi water from Demineralizer + atmospheric tank (SMAT) PUMP+PRESSURIZED TANK Reformate to SOFC stack 14

CH 4 Conversion (%) FUEL PROCESSING (II) Mixed steam+dry reforming Ni-based catalyst: Commercial catalyst composed of 20wt% of Ni supported on - Al 2 O 3 (63wt%) and CaO (5.

15 CH 4 Conversion (%) FUEL PROCESSING (II) Mixed steam+dry reforming Ni-based catalyst: Commercial catalyst composed of 20wt% of Ni supported on - Al 2 O 3 (63wt%) and CaO (5.5 wt%) mixture Catalytic activity suffers the presence of sulfur compounds in the inlet gas stream (H 2 S conc. 0.4 ppm); while the presence of hydrocarbon compounds (conc. 200 ppm) and siloxane (D5 conc. <1 ppm) result less harmful. H 2 S poisoned biogas steam reforming test (CH 4 /CO 2 =55/45%vol.) H 2 O/CH 4 =2 mol/mol; GHSV=10,000 h -1 ; T=1073K; p= 1bar H2S = 2 ppm H2 S= 1,6 ppm H2S = 1 ppm H2S = 0,4 ppm Time (h) 15

16 FUEL PROCESSING (III) Evaporator mixer Reformer IN Inlet connections for: Biogas Demi water H2/N2 OUT 16

17 FUEL PROCESSING (IV) Evaporator inlet Demi water MFC N2 and H2 MFC Reformer outlet Component/Unit Operation H 2 [SLPM] N 2 [SLPM] Processing (CNR) Start-up/Shut-down Stand-by

18 SOFCOM Demo Plant Units Cleaning Unit Fuel Processing SOFC Stack Unit Oxy-combustor CO2 separation Unit Algae Water Treatment 18

19 SOFC STACK UNIT (I) Reformate SOFC Anode exhaust N-H mix for Start-up and stand-by => N-H mix from the reformer MFC AIR PRE-HEATER Cathode air BLOWER HX CHP Tap water for CHP Tap water for CHP Cathode exhaust 19

SOFC STACK UNIT (II) SUNFIRE SOFC Stack 2 kwe

Component/Unit SOFC Stack (POLITO) Operation

20 SOFC STACK UNIT (II) SUNFIRE SOFC Stack 2 kwe 90 cells, 3YSZ SOFC working temperature = 800 C. Inlet fuel temperature = 750 C. Inlet air temperature = 650 C. Component/Unit SOFC Stack (POLITO) Operation H 2 [SLPM] N 2 [SLPM] Start-up/Shut-down Stand-by

21 SOFC STACK UNIT (III) DOMEL Brushless blower for cathode air up to 300 mbar FACO CHP recuperator from cathode exhaust ( C) 21

22 SOFC UNIT (IV) SUNFIRE Air recuperator (from ambient to 550 C). Air electrical heater (from 550 to 650 C). Fixed connection between the SOFC stack and the air pre-heater Development of a common layout with reformer and oxy-combustor partners in order to avoid interferences. 22

23 SOFCOM Demo Plant Units Cleaning Unit Fuel Processing SOFC Stack Unit Oxy-combustor CO2 separation Unit Algae Water Treatment 23

24 OXY-COMBUSTOR (I) Tap water for cooling Oxygen Cooling air COOLER Anode exhaust Anode exhaust Cooling air OXY-COMBUSTOR A venting is inserted here Tap water for cooling 24

$gases composed mainly of H 2 (15%max) CO (7%max), CO 2, H 2 O very efficient operation i.e. mole fraction of unburned H 2 and CO < 0.$ 2 % pressure drop of the gases from SOFC stack on the burner should be lower than 20 mbar silicon carbide (SiC) porous

2 % pressure drop of the gases from SOFC stack on the burner should be lower than 20 mbar silicon carbide (SiC) porous

25 OXY-COMBUSTOR (II) oxy-combustor: operation in high temperatures, in range C ability to burn lean mixtures of gases composed mainly of H 2 (15%max) CO (7%max), CO 2, H 2 O very efficient operation i.e. mole fraction of unburned H 2 and CO < 0.2 % pressure drop of the gases from SOFC stack on the burner should be lower than 20 mbar silicon carbide (SiC) porous foam (porosity 0.86) air-cooled inlet oxgen from cylinders water cooler at combustor outlet until 77 C. 25

26 OXY-COMBUSTOR (III) Porous SiC, layout 1 Porous SiC, layout 2 Catalytic oxy-combustor, water quenching required 26

27 OXY-COMBUSTOR (IV) 3 layout developed by IEN, one still under testing The porous oxy-combustor (layout 1 and 2 have the same dimensions) has been chosen and used for the demonstration plant blueprint because: - It can be placed horizontal => Shorter connection pipe with the stack outlet. - It does not require water quenching => Smaller amount of demi water from the demineralizer. Final hot-box layout 27

28 OXY-COMBUSTOR (V) Final hot-box layout REFORMER AIR PRE-HEATER Inlet and outlet connections from the stack will only require insulation due to short interconnection pipes. => NO electrical tracing POROUS OXY-COMBUSTOR SOFC STACK 28

29 SOFCOM Demo Plant Units Cleaning Unit Fuel Processing SOFC Stack Unit Oxy-combustor CO2 separation Unit Algae Water Treatment 29

30 CO2 SEPARATION (I) Anode exhaust Tap water CONDENSER CMP CO2 MEMBRANE Tap water Air for the cooling fan 30

31 CO2 SEPARATION (II) Condenser unit. Compressor up to 8 bar. Membrane separator (BEKO Technologies type 08-28A Drypoint M Plus) 100% CO2 (H 2 O 500 ppm) with purge gas recirculation From Oxy-Combustor Mixing with purge gas Wet purge gas Needle valve for purge gas adjustment Membran Dry process gas 31

32 CO2 SEPARATION (III) Inlet connection Compressor Drypoint membrane Final check tests on November 2013 Shipping to POLITO on Dicember

33 SOFCOM Demo Plant Units Cleaning Unit Fuel Processing SOFC Stack Unit Oxy-combustor CO2 separation Unit Algae Water Treatment 33

34 ALGAE WATER TREATMENT (I) CO2 - from the demo plant - from cylinder PBR TANK Algae Waste water MEMBRANE Treated water 34

35 ALGAE WATER TREATMENT (II) Inlet streams: waste water (10 mg N/l + 1 mg P/l) CO 2 (dissolved concentration before inhibition 550 ppm) Outlet streams: treated water, O 2 and CO 2 vented, algae purge. Algae production: 20 g/m 2 /day (0.77 g/l/day) 35

36 ALGAE WATER TREATMENT (III) Photobioreactor Pumps, tank and membrane placed behind the PBR 36

37 EQUIPMENT LIST P&ID of the plant units Equipment list with required items and supply partner Auxiliary services definition and requirement calculation Power Supply calculation Control system definition Demonstration plant layout drawing 37

38 AUXILIARY SERVICES (I) N2 users: - Cleaning Unit (bed substitution once a month) - Fuel Processor (start-up and stand-by) - SOFC (start-up and stand-by) => mixed with H2 in the Processing Unit - Emergency Nitrogen Parameter Max Nom Min Total flow rate [NLPM] Available temperature [ C] Available pressure [barg]

39 AUXILIARY SERVICES (II) H2 users: - Fuel Processor (stand-by) - SOFC (start-up and stand-by) => mixed with N2 in the Processing Unit Hydrogen Parameter Max Nom Min Total flow rate [NLPM] Available temperature [ C] Available pressure [barg]

40 AUXILIARY SERVICES (III) O2 users: - Oxy-combustor (continuous flow rate during operation) Oxygen Parameter Max Nom Min Total flow rate [NLPM] Available temperature [ C] Available pressure [barg]

41 AUXILIARY SERVICES (IV) CO2 users: - Photobioreactor (used when the demo plant is not feeding the PBR). Carbon dioxide Parameter Max Nom Min Total flow rate [NLPM] Available temperature [ C] Available pressure [barg]

42 AUXILIARY SERVICES (V) Demi water users: - Fuel Processor (continuous flow during reformer operation). Demi water stored in pressurized tank. Demi water Parameter Max Nom Min Total flow rate [NLPM] Available temperature [ C] Available pressure [barg]

43 AUXILIARY SERVICES (VI) Tap water users: - SOFC Unit (tap water for the CHP heat-exchanger) - Oxy-combustor (tap water used for exhaust cooling) - CO2 separation (tap water used in the condenser) Tap water Parameter Max Nom Min Total flow rate [NLPM] Available temperature [ C] Available pressure [barg]

44 AUXILIARY SERVICES (VII) Waste water - Photobioreactor (continuous flow during PBR operation) Parameter Max Nom Min Waste water Total flow rate [NLPM] Available temperature [ C] Available pressure [barg]

45 AUXILIARY SERVICES (VIII) Instrument air users: - Pneumatic Valves Instrument air Pressure = 4 barg Filtered and oil free (Max. oil content ppm; max dust content 0.01 μm) Dehumidified (Dew point 20 C max.) 45

46 POWER SUPPLY (I) Line V AC Line V DC 46

list with estimation of the un-completed issued concerning the

47 CONTROL SYSTEM Starting from the data about the control system related to each single unit (partner supply), the overall signals list with estimation of the un-completed issued concerning the control system and consequently the operation of the plant, has been made. 47

48 DEMO PLANT LAYOUT (I) Detailed sizing (IEN+POLITO) of the connection between oxy-combustor and cooler to reduce the stream temperature before the HX (AISI 304) => pipe length = 1 m 48

49 DEMO PLANT LAYOUT (II) CO2 separation Air CHP Reformer Air pre-heater Cooling Oxy-combustor SOFC Cleaning system 49

50 DEMO PLANT LAYOUT (III) 50

second 3 units (Oxy-combustor + CO2 separation +PBR) February 2014 Complete assembly of

51 FUTURE DEADLINES December 2013 January 2014 Demonstration plant installation Start-up of the first 3 units (Cleaning + Reformer + SOFC) Installation and start-up of the second 3 units (Oxy-combustor + CO2 separation +PBR) February 2014 Complete assembly of the DEMO March/August 2014 Start-up and operation period (6 month) of the overall demo plant 51

52 DEMO: WWTU-SOFC-CO2 recovery: Deliverables Deliverable Number Deliverable Title Lead beneficiary number Nature Estimated indicative personmonths Dissemination level Delivery date Basic design for a biogas D6.1 cleaning system for a first proof-of-concept SOFC system in Torino Installation and operation of D6.2 the biogas production system D6.3 Installation and operation of the biogas cleaning system Installation and operation of D6.4 the biogas processing system D6.5 Installation and operation of the SOFC CCHP system Installation and operation of D6.6 the O2 separation and anode exhaust catalytic burner Installation and operation of D6.7 the CO2 separation from anode exhaust Installation and operation of D6.8 the CO2 management and disposal system Analysis of the specific test D6.9 session on the complete system Analysis of the monitoring on D6.10 the complete system on the long run Analysis of all the repair and D6.11 maintenance activities developed on the complete system 2 1 R PU M D RE M D RE M D RE M D RE M D RE M D RE M D RE M R PU M R PU M R PU M36 Total

53 Any question? Marta Gandiglio Andrea Lanzini Massimo Santarelli 53

SOFCOM A project financed in the frame of Fuel Cells and Hydrogen Joint Undertaking WP6. of-concept plant 1 (Italy: 5 kw CCHP, WWTU biogas)

SOFCOM A project financed in the frame of Fuel Cells and Hydrogen Joint Undertaking WP6 Design, development and test of the proof-of of-concept plant 1 (Italy: 5 kw CCHP, WWTU biogas) Prof. Massimo Santarelli,