Demonstration of Technology Options for Storage of Renewable Energy

Transcription

1 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

2 Introduction Outline Technology Needs and Challenges Technology Options Pursued at Ceramatec Electrochemical (Solid Oxide) Technology Fuel Reformation Liquid Fuel Synthesis Summary

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

4 Where can we apply integrated solution Population/ Standard of Living Energy Need Geo- Political Emissions Global Warming Renewable Energy Petroleum Need Storage

5 Increase in Standard of Living & Energy Demand Shell International, Energy Needs, Choices and Possibilities, Scenarios to 2050, London, 2010

6 Sources Oil Biomass Gas Coal Nuclear Renewable Energy Forms Electricity Heat Motive Power Challenges Supply/ Demand Conversion Tranportation Storage Efficiency Emission

7 Ceramatec s Focus Areas Renewable Energy Abundant Location Constraint Electrochemical High Efficiency Technology Maturity? Scale up & Cost? Consumes CO 2" Alternative to Sequestration" Synthesis Gas Source of Heat, Electricity, Chemicals Liquid Hydrocarbon High Energy Density Transportability" High Demand"

8 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 CO 2 and H 2 O ü Reformation of methane containing gases Stranded natural gas Biogas Landfill gas Syngas to Liquid Fuels ü Fischer Tropsch

9 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

10 Electrolysis Is The Key To Synfuels Leverage decades of SOFC R&D Inputs e - (green electrons) steam => hydrogen co-electrolysis of H 2 O + CO 2 => 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 O 2 and steam byproducts Valuable for biomass gasification

11 Synfuel Power Market Much Larger Than Grid Electrolysis at V/cell $25/MW-hr Syngas cost $80/bbl Conventional Electric Load US Crude Oil Imports Annual US Electrical Energy Demand GW-hr 4,119,388 47% of Capacity Petroleum equivalent k-bbl Synfuel electric energy as ratio to current demand 1,801,874 1x 470 GW 3,580,694 2x 940 GW US Crude & Refined Imports 4,726,994 $80/bbl 2.6x 1,220 GW US Crude Oil Refinery Inputs 5,361, x 1,410 GW US Crude & Refined Refinery Inputs " " 6,277, x 1,650 GW Grid stability restricts wind to ~ 1/6 of load and requires costly reserve "

12 Liquid Hydrocarbon Energy Density and Value Energy Density Diesel 42 MJ/kg, 0.86 kg/liter Hydrogen at 690 bar (10,000 psi) Z= 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 CO 2 to $ 85/ton of C for crude oil

13 Electrochemical Technologies Renewable Energy + Carbon dioxide Recycle at ~ 100% Efficiency à Synthesis Gas

14 One Technology - Multiple Modes Of Operation Solid Oxide Stack Module NG Biogas Diesel JP-8 Coal Fuel Syngas (CO + H 2 Electricity CO 2 & Steam + Electricity Steam + Electricity Hydrogen (High Purity)

15 Co-electrolysis Reaction Paths [2] [3] [1] [1] H 2 O + 2e - H 2 + O 2- (electrolysis of steam) kinetics favored [1] CO 2 + 2e - CO + O 2- (electrolysis of CO 2 ) kinetics slower [2] CO 2 + H 2 CO + H 2 O (reverse water gas shift ) kinetics fast [3] Reverse shift reaction: CO 2 + H 2 <==> CO + H 2 O As steam is consumed and H 2 produced, the RWGSR converts CO 2 to CO

16 Scale up & Demonstration 720 Cell System Hydrogen Production: 5.7 Nm 3 /hr! 18 kw Steam Electrolyzer (Ceramatec Stacks tested at Idaho National Labs.)

17 Technical Challenges Air electrode delamination Chromium poisoning Seal challenge (back pressure from product collection) High steam corrosion of metal interconnect

18 Electrolysis Stack Stability Progress

19 Recent SOEC Stacks Meet Life2me Targets Steam supply failure ASR Limit for 40,000 hr life2me target 19

20 Molten Salt Electrolysis anode CO 2 in cathode O out 2 CO out 2- CO2 + O CO 2-3 O 2-2e 1 2 O 2 2- CO + 2e CO + 3 2O 2- melt of Li 2 CO 3 Thermal neutral voltage: 1.46V/cell Faradaic efficiency: 100 % Thermodynamic efficiency: 100% Cell voltage: 1.05±0.05V Current density: 100 ma/cm 2 No Degradation in 700hr test Demonstrated at Weizmann Inst., Israel (5000 A cell) Operating Principle & Efficiency same as SOEC Near term scale up possible

21 Reformation Process for Syngas Generation Stranded Natural Gas Biogas (Anaerobic Digester) Landfill Gas

22 Low Power Plasma Reformation 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"

23 1 Low Power Plasma: Liquid/Gas Fuel Reformation Large reformer Can process 100 thousand standard cubic feet/day of Natural Gas (~3000 m 3 / day) > 1 MW thermal Can reform liquid fuels Sulfur tolerant

24 Reformer scale-up 10 TPD Biomass Gasification Reformer + Gasifier * Large reformer * To reform residual tars/oil from 10 TPD biomass gasifier

25 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

26 Ceramatec Laboratory Syngas Facility Two stage oil free syngas compressor with syngas drying system. Discharge pressure psig Final stage oil free compressor. Discharge pressure 800 psig Two 500 gallon, 800 psig syngas tanks; 7200 SCF capacity Inter-stage tank 240 gallon

27 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, 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

28 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

29 Compressor Scale up Capacity equivalent to 2 bpd of FT liquid

30 Pre-pilot Plant Scale up 4 Reactor Tube - Fischer Tropsch Skid! Capacity: 0.25 bpd (40 liters/day)!

31 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

32 FT Demonstration 30 liters/day FT Production Demonstrated"

33 20 15 FT Product Analysis %CN Carbon Number 30 days of continuous operation showed stable performance" 33!

34 Pilot Plant Layout (10 bpd ~ 1,600 liters/day) 100 bpd preliminary reactor concept developed"

35 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 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 H 2 FCV Product compatible with existing dist. & vehicles 20 to 50 years to retire existing fleet

36 FT Process Syngas from other methane sources can be used Biomass based Design options for capital cost reduction Operating strategies for cost reduction

37 Thank You!