The Chemical Plant of the Future: Opportunities Using CHHP Technology

Transcription

1 The Chemical Plant of the Future: Opportunities Using CP Technology Pinakin Patel and Fred Jahnke Presented at Texas Industries of the Future Technology Forum Low Temperature Waste Energy Recovery in Chemical Plants and Refineries May 16, 2011, ouston, TX

2 Types of Fuel Cells Fuel Cell Type Polymer Electrolyte Membrane Phosphoric Acid Carbonate Direct Fuel Cell Future Solid Oxide Electrolyte Ion Exchange Membrane Phosphoric Acid Alkali Carbonate Yttria Stabilized Zirconia Operating Temp. F (650 C) 1800 Charge Carrier CO 3 = O = Cell ardware Carbon /Metal Based Graphite Stainless Steel Ceramic Catalyst Platinum Platinum Nickel Perovskites These electrochemical systems offer unique opportunities for chemical plants of the future 2

3 YDROCARBON FUEL (e.g. Natural Gas) 1,000 F Exhaust ANODE DFC Fuel Cell INTERNAL REFORMING C O 4 2 CO 2 CATALYST ELECTROLYTE CATALYST 2 CO 3= 2 O CO 2 2e - CATODE ½O 2 CO 2 2e - CO 3 = 47% electrical efficiency before using excess fuel ydrogen-based Opportunities for IOF Capturing excess fuel to waste heat provides more high value products 25-35% Excess 2,CO CO2 Power AIR CO 2 Potential benefit to hydrogenation or de-hydrogenation reactions 3 Solid State ydrogen Separator and Compressor Exhaust Gas C4 C4 C4 C4 C4 ydrogen Mixture C4 C4 e- e- e- C4 C4 C4 C4 C4 C4 C4 Anode e- C4 e- ` Proton Exchange Membrane Solid Electrolyte Power Supply CO2 ( OR ) Simple Operating Principle with No Moving Parts Solid State! Use of ydrogen Electrode for igh Compression Efficiency Cathode e- _ e- e- e- ydrogen

4 4 Advanced CP Technology 2 Petrochemicals Materials andling Equipment DFC Power Plant (Electricity ydrogen) Solid State ydrogen Separator (ES) Solid State ydrogen Compressor (EC) Liquid Biofuels MO3145 Peak and Backup Power 1 yr Factory Test at FCE >1.5 yr Site Demo at OCSD (DFC-2-PSA) 100-cell baseline stack tested Advanced CO-tolerant cell technology scaled up to 1000 cm 2 short stack Single cell operated to 12,000 psi Developing Strategic Alliance with ydrogen Users

5 Potential Applications of Solid State Separator 5 Petrochemical Off-Gas ES/EC igh Temperature Fuel Cell igh Pressure CO 2 CO 2 Liquefaction Liquid CO 2 igh Pressure 2 igh Pressure 2 Storage Gasification Petrochemicals / Refining Clean Power Rapid Response, Peak Power Industrial Gas Use Transportation Emerging opportunity for oil and petrochemical industry

6 6 ES for Refinery Applications Refinery / Petrochemical Complex Fuel Gas Natural Gas SMR ydrogen ydrocracker FCCU gas Oil Ethylene off gas 2 Recovery SMR Off-gas Collection / Processing System 2 containing fuel gas Excess ydrogen Low Cost, Low Energy Recovered ydrogen Exhaust Gas - e e Proton Exchange Solid Electrolyte ` Membrane Anode e - Power Supply ( CO2 OR C4 ) _ ES e Cathode e C4 e e CO2 C4 CO2 CO2 CO2 C4 ydrogen Mixture C4 C4 CO2 CO2 C4 C4 C4 igher BTU fuel gas

7 ydrocracker ydrogen Recycle 7 Off-site ydrogen Recovered / _ Recycle 2 _ Pressurized ES 2 Containing Off-gas (S free) _ igh Pressure Off-gas Off-gas 2 Recycle

8 8 Natural Gas SMR Booster SMR ydrogen PSA Added ES ydrogen Reformer Tail Gas Solid State ydrogen Separator (ES) Makeup Natural Gas Solid State ydrogen Separator can Boost SMR Output and Efficiency incremental hydrogen without additional emissions, without major investment

9 9 Chemical Integration / ydrogen Recycle Reformer Other ydrogen Users Natural Gas PSA 2 CO 2:1 1:1 Ref DFC 2 CO Desired Ratio Chemicals Processing Recovered / Recycle 2 _ 2 Containing Off-gas _ DFC igh Temperature Fuel Cell Ultra-Clean CO2/N2/O2 for Algae / Biomass Electrochemical ydrogen Separation (ES) for Ratio Adjustment Pure ydrogen Pressurized ES Off-gas Off-gas 2 Recycle Chemical integration opportunities include 2 to CO ratio adjustment, 2 recycle from processing off-gas and CO 2 for other uses

10 Co-Production of Renewable ydrogen in California Site load ~ 6 MW; up to 300 kw provided from fuel cell Engines on biogas reduced from 13 MW to <4 MW due to NO x constraints Potential using biogas fuel cell: 20 MW 20 MW of peak power and kvar support 10

11 ES Demonstration at UConn >15,000 hrs of Operation in Subscale Stack 11

12 12 EC Technology Development 2009 ydrogen Program Annual Merit Review Award Baseline EC ardware Design Progress in 2 Compression Capability of EC MO3292 Compression capability from atmospheric to 12,000 psig (one stage) Achieved higher current density of 1200 ma/cm 2 Received follow-on funding from DOE

13 What Can We Do With By-Product ydrogen? 13 DFC300 DFC1500 DFC3000 Co-product Power, kw ydrogen, kg/day eat, mmbtu/hr Refueling Capacity Cars, 4.2 kg/day Buses, 25 kg/day ,150 2, , Fork Lifts, 2.1 kg/day Plug- in Battery ybrid, 12 kwh/day 500 2,400 4,800 MO3256A

14 14 Cost Estimates for 2 Co-Production CP System with DFC1500 and PSA Purification ES further improves on these economics

15 awaii SNG Pipeline and Potential ES Locations 15 TGC infrastructure follows the populated core on Oahu

16 16 Direct FuelCell Application for Carbon Separation from Fossil Plant Exhaust Carbonate electrochemical process transfers CO 2 from Air Electrode (Cathode) to Fuel Electrode (Anode) CO 2 is easily separated from Fuel Electrode exhaust gas because it is no longer diluted with air Demonstrated in small cells, needs commercial scale demonstration Fossil Plant Exhaust with 5% to 15% CO 2 CATODE CO 2 Depleted Flue Gas Fuel CO 2 ANODE Depleted Fuel with ~70% CO 2 CO 2 Separation Conventional Natural Gas or Coal Plant DFC Powerplant 30 to 75% of Conventional Plant Rating CO 2 for on-site use

17 17 Relevance to IOF ighly innovative approach to fuel cell development - Internal reforming technology (45-50% electrical efficiency) - Fuel cell-turbine hybrid system (55-65% electrical eff.) - Energy Recovery Technology (60-70% electrical eff.) natural gas pipeline pressure let-down stations refinery off-gas streams containing C1-C4 - Steam generation - Fuel flexible system no performance loss on biogas

18 18 Relevance to IOF Continued innovation for enhanced value proposition - Co-production of renewable 2 and e - (60-70% eff. w/o CP) - Solid state hydrogen separation and compression: - Recover hydrogen from off-gases - Increase 2 production from reforming/smr - Enhance hydrogenation/dehydrogenation processes - 2 for sulfur removal - Advanced high pressure steam generation - Remote power generation, peak power management - Next generation fuel cells (lower temp. SOFC, PEM) - Advanced fuel clean-up technology to ppb level (biogas digester gas and landfill gas, biodiesel, diesel)

19 19 Questions for IOF Forum Participants What are different process streams that involve hydrogen use or release? Reactions involving methane, 2 with higher C? Are there reactions involving CO 2, CO? Interest in GG management (SO x, NO x, CO 2, )? Low-quality NG available that can be converted to 2?

20 20 Thank you Questions? Pinakin Patel Director of Special Systems and Research