Science-to-Business Center Eco² Steigerung der Energieeffizienz industrieller Prozesse durch den Einsatz chemischer Wärmespeicher Dr. Jens Busse Creavis Technologies & Innovation Version 6.0
Contents Evonik Creavis Science-to-Business Center Eco² Motivation Thermochemical heat storage Evaluation of technical implementation Life Cycle Analysis and Summary Page 2
Evonik is structured in a modern way Structure of Chemical Business Area Page 3
Who we are: Evonik s R&D Research, development and innovation are key elements in the strategy for sustainable growth 365 million R&D expenses in 2011 +8 % higher R&D expenses versus 2010 More than 2.300 employees in R&D More than 35 R&D sites worldwide More than 300 cooperations and collaborations worldwide Page 4
Creavis is the strategic R&D unit of Evonik Industries AG Structure of Creavis Creavis Technologies & Innovation New Technology Platforms New Business Development Science-to- Business Bio Science-to- Business Eco² Advanced Project House Light & Electronics Project Solar 1) Corporate Foresight Life Cycle Management Internal Start-up CGTR Strategic Controlling Communication & PR Production & Technology Marketing 1) Originated from concluded S2B Nanotronics 2) part of S2B Eco 2 Page 5
Science-to-Business Center Eco² is driven by the megatrend Resource Efficiency November 2011 Strategic Approach of Eco 2 Background Approach Targets Megatrend Resource Efficiency Competence development via multi-disciplinary skilled and diversity driven people Open innovation in an extensive external network Cutting-edge innovation management Significant and sustainable CO 2 reduction at customer and in Evonik group Midterm realization of high share of EBITDA potential Stakeholder communication Offering customers value-added sustainability solutions is a good way to differentiate from competitors. Page 6
The S2B Eco 2 pools the group s energy efficiency and climate protection expertise Science-to-Business Center Eco² Energy Efficiency and Climate Protection Lines of Development CO CO 2 2 Separation and and Use Use Energy Energy Generation Energy Energy Storage Energy Efficiency Generation Storage Customer Solution Life Cycle Management Energy Efficiency Evonik Processes Corporate BU s Services Page 7
We would like to generate energy out of alternative energy resources and waste heat as per Jan 2013 S2B Eco² Line of Development Energy Generation Background Approach Targets Required energy generation without CO 2 emissions A large part of waste heat is directly emitted into the environment and thereby not exploited Development of new technologies and the preparation of solutions for energy generation 1) direct, through Biomass utilization Renewable hydrogen production 2) indirect, through Use of residual heat CO 2 neutral energy generation by means of renewable energy and resources Decrease the carbon footprint through an increase in energy efficiency Provide CO 2 neutral energy for a sustainable and secure future supply. Page 8
Contents Evonik Creavis Science-to-Business Center Eco² Motivation Thermochemical heat storage Evaluation of technical implementation Life Cycle Analysis and Summary Page 9
Energy data are gathered for nearly all European Evonik sites by means of SitEModel and EEM 1) SitEModel and Efficient Energy Management SitEModel Site Energy Modelling Site comprehensive modelling, simulation and analysis of the loadsensitive energy consumption. Efficient Energy Management Coworkers of the sites develop together with experts improvement activities to increase energy efficiency. 1) EEM: Effizient Energy Management page 10
Saving potentials in different height can be found on each chemical site Results of Efficient Energy Management and SitEModel Between 2006 and 2008 EEM was performed at 26 Evonik sites. Approx. 250 optimization measures with a saving potential of 12,6% of the yearly energy cost have been developed. El. Power 2% 6% 13% Gases 9% Others Cooling Heat is the most important utility to increase energy efficiency. 70% Heat The Efficient Energy Management was being granted by the Deutsche Energie-Agentur GmbH with the "Energy Efficiency Award 2009" page 11
The major part of waste heat in the chemical industry is available below 150 C Waste heat from refining and chemical industry* Spoelstra et al; 1999;* in the Netherlands page 12
The major part of waste heat in the chemical industry is available below 150 C Waste heat from refining and chemical industry* Heat Storage Spoelstra et al; 1999;* in the Netherlands page 13
The major part of waste heat in the chemical industry is available below 150 C Waste heat from refining and chemical industry* Heat Storage Heat Pump Spoelstra et al; 1999;* in the Netherlands page 14
The combination of a heat pump and a heat storage system offers the opportunity to increase the energy efficiency of chemical processes Combination of a heat pump and heat storage system Design of a new process for the utilization of waste heat for the energetic use in different applications e.g. batch processes. Development of a combined system with an absorption heat pump with new working fluids based on inoic liquids and a thermochemical heat storage system with high storage density. Source: Yasaki Heat source Heat pump Heat storage Heat sink SIT project with DLR Duration 2010-2013 Sponsored by the: Source: DLR page 15
Contents Evonik Creavis Science-to-Business Center Eco² Motivation Thermochemical heat storage Evaluation of technical implementation Life Cycle Analysis and Summary Page 16
For the utilization of waste heat we need a heat storage system with a maximum capacity Storage densities of different heat storage systems in kwh/m³ 400 100 130 50 sensible 1) latent sorptive chemical ;1) Water at a T of 50K page 17
Upon heating the heat storage material is split into two components Operational mode of chemical heat storage (1/2) AB (s) + heat A (s) + B (g) Cooling water to process A AB B Heat from process (s) = solid (g) = gaseous page 18
Upon recombination of the components the stored heat is regenerated and can be used for process heating Operational mode of chemical heat storage (2/2) AB (s) - heat A (s) + B (g) Water A AB B Heat to process (s) = solid (g) = gaseous Storage densities and cycle stability are important requirements to heat storage materials page 19
SIT 2 fullfils the requirements defined for storage density, working temperature range and cycle stability/reversibilty in collaboration with Energy storage densities in kwh/m³ 400 400 520 210 330 200 290 330 430 240 300 SIT1 SIT2 SIT3 SIT4 SIT5 SIT6 SIT7 SIT8 SIT9 SIT10 Equilibrium temperatures in C (at 1 bar) 380 143 174 150 107 87 89 105 119 157 200 100 SIT1 SIT2 SIT3 Cycle stability/reversibility SIT4 SIT5 SIT6 SIT7 SIT8 SIT9 SIT10 page 20
Contents Evonik Creavis Science-to-Business Center Eco² Motivation Thermochemical heat storage Evaluation of technical implementation Life Cycle Analysis and Summary Page 21
The process scheme for the new thermochemical heat storage system is simple and modular Heat storage system components Viskosität 5000 mpas Dichte ca. 1800 kg/m³ Vorlage - wasserfrei Storage SIT2 Vorlage enthält Storage Wasser SIT2 + R P 01 W 01 Wasser R Connection to process page 22
Batch reactions need a lot of heating and cooling energy for each step Typical temperature profile in a batch reaction 120 Reactor temperature Temperature [ C] 100 80 60 40 20 0 0 50 100 150 200 250 300 350 400 450 Time [min] Heating (qualitative) Cooling (qualitative) page 23
In case of exothermic reaction it is possible to store heat energy during the reaction Exothermal batch reaction with heat storage 120 100 Reactor temperature Storage temperature Temperature [ C] 80 60 40 20 100 50 State of Charge Storage 0 0 0 50 100 150 200 250 300 350 400 450 Time [min] Heating (qualitative) Cooling (qualitative) page 24
The utilization of a heat pump in combination with the storage system allows to increase the efficiency of waste heat utilization Exothermal batch reaction with heat storage and heat pump 120 Reactor temperature Storage temperature Temperature upgrade by additional use of heat pump 100 Temperature [ C] 80 60 40 20 100 50 State of Charge Storage 0 0 0 50 100 150 200 250 300 350 400 450 Time [min] Heating (qualitative) Cooling (qualitative) Heat Pump (qualitative) page 25
Contents Evonik Creavis Science-to-Business Center Eco² Motivation Thermochemical heat storage Evaluation of technical implementation Life Cycle Analysis and Summary Page 26
The whole lifecycle for SIT 2 as heat storage material was evaluated Life-Cycle of heat storage material SIT 2 Sourcing: Raw material sources were assessed Raw materials are available in large quantities Disposal: Re-utilization of SIT 2 as heat storage material is the prefered option Re-utilization of SIT 2 in alternative applications is possible in large quantities Disposal options were evaluated Production: Suitable locations for a production plant for heat storage materials were identified A world-scale production plant is needed to satisfy the demand Logistics: Multiple transport options were economically and ecologically assessed Customer and material requirements regarding packaging of heat storage material were evaluated Utilization: In-use savings of greenhouse-gas emissions were evaluated page 27
The reduction of CO 2 emissions in the use phase compensates the burden for the production of the heat storage after few utilization cycles Specific CO 2 -Emissions of selected heat storage materials Material Emissions 1) Kg CO 2 e/m³ Spec. emissions Kg CO 2 e/kwh installed Min. Cyclenumber 3) SIT 1 ~400 ~1,00 4 SIT 2 ~1000 ~2,40 9 SIT 5 ~200 1200 2) ~0,6 3,6 2-13 SIT 8 ~8200 ~25 92 Source: PE, LBP: GaBi 4 Software-System and Databases for Life-Cycle Engineering ; Frischknecht R. et al (2007) Overview and Methodology. Eocinvent report No. 1. Swiss Centre for Life Cycle Inventories, Dübbendorf; 1) under consideration of the porosity; 2) Depending on the production process; 3) spec. emissions of heat generation using natural gas 0,23 kg CO 2 e/kwh page 28
Within the first two years all technical goals of the project were reached Summary An suitable heat storage material was identified Characterization of thermochemcial properties and technoeconomical and ecological assessment were carried out Thermal power of up to 350 W was achieved for solid phase reaction and up to 1kW for operational modes with phase transition An reactor concept for the reaction system is identified that enable high heat storage density Project SIT with DLR Duration 2010-2013 Sponsored by the: page 29
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