HTR Process Heat Applications
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1 HTR Process Heat Applications Training Course on High Temperature Gas-cooled Reactor Technology October 19-23, Serpong, Indonesia Japan Atomic Energy Agency
2 HTR Heat Applications Hydrogen production Hydrogen supply Fuel-cell vehicle Hydrogen reduction ironmaking Chemical production 900 ~ Fuel: U, Pu, Th, MOX HTGR 950 ~ 750 Electric generation system (Using gas & steam turbine) Electricity supply People s livelihood Private electric generation Intermediate heat exchanger Steam generator Waste heat utilization Efficient heat utilization District heating Desalination Hot water aquaculture Heating cultivation 150 Cooler ~ ~ 600 High-temperature steam supply system Process steam supply Chemical industry Petroleum refining H 2 potentially substitutes for fossil fuels in heat utilization field H 2 production process converts nuclear energy into H 2 Heat source for various heat applications p.2
3 Contribution to Heat Current energy systems heavily depends on fossil resource. CO 2 output 1.2 billion ton CO 2 (2008 year) Heat utilization field 27% 18% 13% 11% 23% H 2 is expected to substitute fossil resource in heat utilization field. Energy form (Secondary energy) Resources (Primary energy) Electricity generation Transportation Civil area sector Electricity 40% Nuclear 11% Heat 60% Fossil resource 83% Natural energy 6% Green house gas emissions in Japan (2008) 1) 1) Agency for Natural Resources and Energy, FY 2010 Annual Energy Report, 2011., Ministry of Environment, 2008 Volume of greenhouse gas emissions, Miscellaneous Cement, paper 4% Chemical industry 4% Steel manufacturing Nuclear H 2 production from H 2 O offers Mass production capability with competitive cost Superior energy security Reduction of CO 2 emission in heat utilization field Reduction of fossil resource usage p.3
4 Why Hydrogen? Hydrogen acts as energy carrier + Energy 2H 2 (g) + O 2 (g) = 2H 2 O(l) kj Advantages Can be produced from H 2 O no limitations of feedstock Changes into water by combustion no environmental pollution Small loss in transport pipe lines, tankers Various storage technologies high pressure gas, liquefied hydrogen, metal/organic hydride Wide range of usage fuel, reducer for chemical industry and ironmaking, power conversion for electricity p.4
5 H 2 Production with Nuclear Energy Nuclear energy Primary energy Light-water reactor (LWR) < 325 o C Fast breeder reactor (FBR) < 550 o C High temperature gas-cooled reactor (HTGR) o C Electricity Electricity Heat Electricity Heat Energy forms Heat Fossil fuels Electricity Electricity Heat Heat Electricity Heat Feedstocks Water Hydrocarbon Water Water Water Water Methods Steam reforming Electrolysis Hightemperature Steam electrolysis Thermochemical water-splitting Hybrid thermochemical water-splitting (Hybrid-TC) Hydrogen p.5
6 Methane Steam Reforming using Fossil Fuel Steam reforming reaction (endothermic) CH 4 + H 2 O CO + 3H 2, ΔH=206 kj/mol Water gas shift reaction (exothermic) CO + H 2 O CO 2 + H 2, ΔH= 41 kj/mol Energy Commercialized method and widely use in the world Produce greater part of worldwide H 2 production Use combustion heat of methane Methane Steam reforming plant HTGR coupled steam methane reforming plant can Early deployable because the technology in H 2 production section is matured Can save methane and reduce Co2 emission by supplying heat by nuclear reactor p.6
7 Alkaline Water Electrolysis Industrialized, mature technology Operating temperature, o C Alkali solution (KOH 20 30%) Theoretical decomposition voltage, 1.3 V at 25 o C Alternative to asbestos diaphragm Challenges for further improvements Overvoltage reduction by catalyst electrode Corrosion-resistant materials in high conc. KOH soln. over 100 o C Mitigation of limitation of operating current density by resistance from gas existence p.7
8 High Temperature Steam Electrolysis Higher temperature, lower voltage (=smaller electric energy) Theoretical decomposition voltage, ca. 0.9 V at 1000 o C Solid oxide electrolyte (oxygen ion conductive; e.g. yttria stabilized zirconia (YSZ)) Cells are built mostly of ceramics material Plate type cell or cylindrical type cell External heating (higher eff.) or autothermal Challenges Upsizing ceramics parts Reduction of performance degradation Durability against thermal cycle p.8
9 Thermochemical Cycle Chemical process for water splitting Suitable for on-site production in large volume Advantages Thermochemical water-splitting cycle has the same function as heat engine Smaller electricity demand than electrolysis Realistic operating temperature well suited for industrial plant Possibility of higher thermal efficiency Possibility of higher scale merit in economic terms p.9
10 Desirable thermochemical cycle Desirable features Small number of chemical reactions Small number of elements Temperature range consistent with heat source temperature Liquid/gas phase operation High thermal efficiency and low cost p.10
11 Copper-chlorine cycle Number of reactions: 3 Number of element: 4 Maximum temperature: 500 o C (matching Super-Critical Water Reactor) Including solid handling One electrochemical reaction Practicability for elemental reactions were demonstrated separately on lab-scale p.11
12 Iodine-sulfur (Sulfur-iodine) process Number of reaction: 3 Number of element: 4 Maximum temperature: 900 o C Full liquid/gas phase operation Not including Widely investigated in the world electrochemical reaction (May use electricity in concentration of HI) (Japan, USA, France, Korea, China.) Lab-scale integrated cycle was demonstrated p.12
13 Technical challenges for thermochemical cycles Construction materials Thermal, corrosion resistance Chemical engineering Separation of object substances from reactants, by-products Purification to remove minor components Solid substance handling Process thermal efficiency Low conversion in reactions Difficulty in separations Hydrogen production cost Need breakthrough to improve thermal efficiency Construction material is expensive p.13
14 High Efficient Power Generation Electricity generation Key process parameters 1) (design example) Heat (He) Elec. Reactor Gas turbine High generating efficiency (46.8%) is expected Simplicity of equipments configuration (no water handling, no secondary system) Closed regenerative Brayton cycle 1) X. Yan et al., Nucl. Eng. Des., 222 (2003) High-T and high-p Helium gas circulates through a loop composed of gas turbine, recuperator, precooler, compressor and reactor. p.14
15 HTGR-GTL Combined Process Gas to liquids (GTL) is a refinery process to convert natural gas into liquid synthetic fuels such as gasoline or diesel fuel. HTGR (High Temperature Gas-cooled Reactor) produces high temperature steam to be used mainly for the gas synthesis process. GTL process Air Air Separation Natural Gas Gas Processing HTGR Gas Synthesis 850 degrees FT(Fischer-Tropsch) process Upgrading Process degrees degrees Diesel Naphtha Parafin p.15
16 H2 Reduction Steel Making Process Present Blast furnace steelmaking (70% of crude steel production) 2) Price fluctuation of material coal Reduction of iron ore by material coal {(2n+0.5m)/3}Fe 2 O 3 + C n H m {(4n+m)/3}Fe + nco mH 2 O Direct reduction steelmaking No CO 2 emission in reduction Material coal free Hydrogen steelmaking (future) Reduction of iron ore by hydrogen Fe 2 O 3 + 3H 2 2Fe + 3H 2 O Iron ore Pelletization Scrap Casting Pelletization Iron ore Sintering Lime Coal Direct reduction Coal Coke Blast furnace Converter Refining Refining Electric arc furnace Scrap Natural gas etc. Slab Billet Bloom 1) World Steel Association, Overview of the steelmaking process, ) World Steel Association, Steel Statistical Yearbook (Data in 2012) p.16
17 Concept of HTGR Steelmaking Plant Water IS process Shaft furnace Electric arc furnace HTGR Heat Hydrogen Electricity Iron ore Direct reduced iron High quality steel Heat Helium gas turbine Electricity Material Heat, electricity IS process produces H 2 HTGR can provide all necessities (heat, electricity, and H 2 ) p.17
18 Desalination with HTGR Gas turbine Large amount of waste heat (248 MWt for 600 MWt reactor power) Reactor Precooler Waste heat Cooling water MSF is provided with power generating installations in the Middle East Fresh water by evaporation incorporating latent heat recovery Considerable economy by upsizing of MSF plants p.18
19 HTTR Heat Application Demonstration Project goal 1. Licensing License acquisition of world s first nuclear GT/H 2 cogeneration plant 2. Operability Confirm safe & reliable operation 3. Complete system technology HTTR Heat utilization system Project plan Design, construction & operation for HTTR- GT/H 2 plant Establish new licensing framework for coupling GT/chemical plant to nuclear reactor Demonstration of key technology (e.g. shaft seal) reliability in system performance Isolation valve H 2 plant 2 nd IHX Reactor Reactor Gas turbine Helium gas turbine H 2 plant Precooler Recuperator IHX HTTR demonstration test system layout IHX Cooler HTTR demonstration test system configuration p.19
20 HTTR-GT/H 2 Plant Outline For H 2 production HTTR-GT/H 2 is designed to simulate commercial GTHTR300 system design and operation modes Thermal power (IHX) 10 MWt IHX heat supply temperature 900 o C GT inlet temperature 650 o C GT pressure ratio 1.3 Turbine flow rate 6-12 kg/s H 2 plant heat load 0.7MWt Reactor 600MW 594 o C 950 o C GTHTR300 Precooler H 2 plant 170MW IHX 850 o C 950 o C HTTR-GT/H 2 plant 10MW 650 o C 850 o C H 2 plant 0.7MW 2 nd IHX 850 o C 650 o C 395 o C 360 o C 150 o C Gas turbine Gas turbine Recuperator Reactor IHX Precooler Recuperator Cooling tower Cooling tower Cooler p.20
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