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Gasification R&D at CSIRO

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Gasification R&D at CSIRO Role of carbon resources in emerging hydrogen energy systems Daniel Roberts, Michael Dolan and David Harris CSIRO ENERGY Overview Challenges: • Growing energy demand 250 Petroleum and other liquids • Scale, cost, reliability, emissions • Renewables integration 200 Coal 150 Opportunities • Changing resource and technology mix Natural gas 100 • Leverage technology and resource mix across energy sectors Renewables 50 – Power, Transport, Chemicals, Manufacturing… Nuclear • Storage and export of renewable & low emission energy 0 vectors is key 1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040 – New approaches needed Source: EIA, International Energy Outlook 2017 Hydrogen energy value chains New renewable energy Enabling H2 energy systems export industry Reducing cost of electrolysis Scalable, intermittency- Decarbonisation of friendly NH3 production heavy transport via technologies direct-fired NH3 engines Distributed non- Ammonia cracking for intermittent Gasification routes for coal and biomass to hydrogen Decarbonisation of renewables personal transport Gasification: a flexible enabling technology Brown Gasification EOR and CO2 storage opportunities Source: Shell 2007 Bringing carbon resources to the challenges of scale Japan’s Clean Coal Technology pathway Underpinned by high efficiency technologies Source: CRIEPI, Japan, 2015 KHI “CO2 free hydrogen chain” Gasification of Australian brown coal with CCS 30JPY ~ US$0.25 Source: Yoshino et al, Feasibility study of CO2 free hydrogen chain utilizing Australian brown coal linked with CCS, Energy Procedia 29 (2012) 701-9 Japan’s vision: Role model as world’s first low carbon society utilising hydrogen by 2030 Hydrogen 9 Mtpa 21Mtpa 34Mtpa Source: Kawasaki Heavy Industries, 2014 Achieving scale across energy sectors H21 Leeds City Gate project Conversion of Leeds natural gas grid to H2. salt cavern NG rig H from SMR: 4 x 250MW/unit (staged) LNG storage 2 CO2 storage • Renewables powered electrolysis and biomass compressor sources challenged by scale, cost, intermittency SMR Salt cavern H2 storage (up to 854,000 MWh Pressure salt of hydrogen storage) reduction cavern compressor pressure • 1.5MT CO2/yr captured and stored control Opportunities for other H2 sources salt power cavern • plant Parallel processes coal, NG, biomass, wind electrolysis etc • Import hydrogen from international renewable hydrogen suppliers https://www.northerngasnetworks.co.uk/2017/H21-Report Research opportunities: Australian Hydrogen Energy Initiatives Several intersecting value chains Renewable Hydrogen Ltd • Consortium developing partnerships to enable renewable ammonia as hydrogen carrier • Engagements with FCV manufacturers, ammonia producers, enabling technologies CSIRO gasification, hydrogen separation and ammonia ‘cracking’ technologies • Fossil fuel, renewable and hybrid pathways • Ammonia cracking technology (BOC, Toyota, Hyundai, Siemens, RH2…) – Engagements Australia, Korea and Singapore in hydrogen car and bus demonstrations • Direct ammonia utilisation (engines, turbines, fuel cells…) • Electrochemical and membrane reactor H2 and NH3 synthesis technologies CSIRO Hydrogen Energy Systems Future Science Platform (FSP) • Step change technology opportunities across the value chain Hydrogen Mobility Australia • Industry initiative to accelerate commercialisation of hydrogen technologies for power, energy storage, transport ARENA - Renewable Hydrogen for Export Research Fund • $20M for hydrogen energy supply chain technology research Syngas & Hydrogen Pathways Renewables eg Solar/Wind H O 2 CO + H H O + C H CH + H O CO + 3 H Electrolysis, 2 2 n 2n+2 4 2 2 Heat Steam Methane Reforming Fischer Tropsch⇌ Synthesis (GTL) ⇌ CH4 + CO2 2CO + 2H2 Dry Reforming ⇌ CO2 + 4H2 = CH4 + 2H2O CO + H2 Methanation 3C +O +H O → H +3CO 2 2 2 Syngas Gasification Pyrolysis CO2 + 3H2 H2O + CH3OH Chemical Looping Combustion (CLC) H2 CO⇌2 Hydrogenation Hydrogen (Methanol Synthesis) Refining Chemicals Powergen N2 + 3H2 2NH3 2NH3 + CO2 H2O + NH2CONH2 Fuel Cells Ammonia Production ⇌ ⇌Urea Production Ammonia Cracking High Pressure & Temperature Brown Coal gasification Fluidised bed gasification • Low temperatures to manage ash (800-950°C) Low-cost gasification for • Large particles (mm-sized) efficient power generation • Atmospheric pressure • Air blown Entrained flow gasifiers are common Coal-to-products requires • Mineral matter must melt and form O2-blown technologies a tappable slag • Operate at high pressures, temperatures, with fine particles. O -firing may be problematic in fluid bed, 2 Limited data & experience transport, and possibly fixed bed for Victorian brown coals technologies (e.g. hot spots in fluid beds) under these conditions Concentrated Solar Thermal technologies Integration of solar energy in thermal and chemical processes Industrial process heat Solar Steam Steam turbine Electricity SMR & WGS processes Solar syngas and H2 Shift Reactor CO2 + H2 25% solar energy embodied Hydrogen production Pilot scale demonstrated to 600kWth Storage Thermal SolarGas Liquid transport fuels via Fischer Tropsch or Methanol Solar HTF Air Electricity Gas turbine – simple or combined cycle Supercritical CO2 Electricity sCO2 Brayton Cycle Heliostat and Receiver Technologies Ammonia for energy storage & transport eg: Pilbara ammonia plant • 80,000 tonne ammonia storage ~$80M • Equivalent to ~200 GWh of electricity • Projected cost of equivalent battery storage: $20-25B Ammonia energy storage – Capital cost – $0.40/kWh – Permanent storage, near zero losses or degradation – Liquefies easily at 10 bar or -33°C – Transportable in bulk, using existing refrigerated ships &carriers – same as LPG Cost of energy storage as ammonia ~0.3% of battery storage * Projected 2030 battery storage cost USD$100/kWh, Source Bloomberg NEF; NH3 conversion to electricity 3.1MWh per tonne Renewable Ammonia – Carbon-free solar fuel and Hydrogen Energy Carrier Unlimited water Ammonia (NH3) resource Synthesiser World’s Electrolysis highest solar resource (2 x Hydrogen (H ) average of 2 Japan). Unlimited, low- Solar Electricity cost land area Air Separation Unit Nitrogen (N2) Renewable . Ammonia (RNH3) Australia Air Japan Renewable Ammonia used as direct fuel, or as Hydrogen carrier RNH3 for Stationary Renewable Ammonia is Electricity Generation shipped using existing bulk ammonia or LPG vessels or or Engine Turbine Renewable Fuel Cell Renewable (carbon-free) Ammonia (RNH3) Waste Heat ~ 350C Electricity Local distribution via H2 common ammonia transport methods - Road, Rail, or Pipeline Fuel Cell Car Renewable Ammonia is reformed as 100% pure H2 BAC 6/02/16 Novel direct ammonia production technology catalytic membrane reactor Prototype proof of concept facility O developed 2 NH3 Low pressure (10-30bar) • ~25% lower energy input than Haber Bosch PEM process Membrane RE Electrolyser H at Reactor Decentralised, modular process 2 35 bar N at High conversion rate and yield 2 35 bar Water RE ASU Catalytic Membrane reactor Single stage production and separation of hydrogen • Separation of H2 from ammonia-derived mixed gas streams • This concept can also be applied to NG reforming, CO shift, or any process which produces H2 as a product. Feed stream (high pressure) NH N2 3 H2 High catalytic activity to H2 dissociation Tolerance to non-H2 species Low transport resistance High thermal stability Feed-side surface Low cost High permeability Catalytic Core Embrittlement resistance alloy layer (200 nm) Low cost V in substrate: USD 180 m-2 Permeate side surface High catalytic activity to H recombination Catalytic layers: USD 2 100 m-2 Low transport resistance plus manufacturing High thermal stability costs Low cost 0.25mm-thick dense metal Pure hydrogen (low pressure) tube Pilot Ammonia ‘cracking’ facility Gen 1 system: • SIEF funding • Membrane area 0.3 m2 (19 x 50 cm tubes ≈ 15 kg/day at 80% yield) • 2-3 cars/day • Located at CSIRO Brisbane, commissioning 2018 Gen2 plant: • 3 m2 of membrane area (100 m) • 150 kg/day (~3 buses per day) • Possible locations: Qld, Singapore, Korea… Summary High efficiency carbon technologies will play a key role in achieving long term emissions and performance targets • Increasing efficiency is a prerequisite for effective CO2 capture and storage • Value added approaches reduce cost impact of CCS • Platform for integration of renewables across energy sector R&D challenges to increase efficiency, improve reliability, reduce costs • Gasification provides a high efficiency technology platform for hydrocarbon energy systems – Development pathway for power, hydrogen and polygeneration systems • New research in key areas where breakthroughs will improve cost and reliability – biomass and waste to energy systems – Creating new industries around hydrogen energy systems and exportable renewables • Hybrid carbon/solar value chains address intermittency, storage and scale issues International partnerships are needed to facilitate research, development, demonstration and deployment Thank you David Harris Research Director: Low Emissions Technologies CSIRO Energy e: [email protected] CSIRO ENERGY.
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