Demonstration of the Novel Process at the Hynor Lillestrøm Hydrogen Station (Norway)
Hydrogen Production from Biogas by Sorption-Enhanced Steam Methane Reforming (SE-SMR) Demonstration of the Novel Process at the HyNor Lillestrøm Hydrogen Station (Norway)
Julien Meyer Institute for Energy Technology (IFE) Department of Environmental Technology www.ife.no; [email protected]
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012 Outline
• The HyNor project
• The HyNor hydrogen station at the city of Lillestrøm
• The Sorption-Enhanced Steam Methane Reforming process (SE-SMR) for hydrogen production with integrated CO2-capture
• The SE-SMR pilot unit at the Hynor Lillestrøm station
• Foreseen test plan
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
The HyNor project The hydrogen “highway” in Norway
www.hynor.no
• Demonstration of hydrogen production technologies for the introduction of hydrogen as transportation fuel in Norway • Make possible driving between the cities of Oslo and Stavanger with hydrogen vehicles
• Sweden, Danmark and Germany also have similar hydrogen road projects • Hydrogen Sweden • Hydrogen Link • Clean Energy Partnership (CEP)
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
The HyNor Lillestrøm project www.hynor.no/romerike http://hynor-lillestrom.no
Lillestrøm
• Hydrogen production based on renewable energy • From landfill gas produced at a nearby landfill and transported by pipe to the station • From electrolysis using power from the grid and from photovoltaic panels installed at the station • Hydrogen compression to 700 bar • Conventional mechanical compression • Demonstration of a metal hydride compressor delivering at 200 bar • On-site hydrogen delivery (dispenser) • Hydrogen vehicles fleet: 4 Think Hydrogen
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
Project participants and financing
• Hynor Lillestrøm AS: project owner • Institute for Energy Technology (IFE): project leader • Akershus Energi AS: building and infrastructure • Technology suppliers • IFE: Reformer unit and system integration • HyGear: Landfill gas upgrader • Power + Energy: Hydrogen purifier • H2-Logic: Electrolyzer, compression & storage, dispenser • Hystorsys: Metal hydride compressor • Scandpower AS: Risk analysis and safety • Financed by • Akershus County (Akershus Fylkeskommune) • Research Council of Norway through the RENERGI-program • Transnova (governmental trial funding program) • Innovation Norway
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
The Akershus Energy Park energy, research, education
http://www.aeas.no/pages/akershus-energipark
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
The Akershus Energy Park
Service Building / R&D Building / Training Center Hydrogen Station
Energy Plant
2009 2010 2012
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
HyNor Lillestrøm System Concept
• Production capacity 3 • 10 Nm /h H2 from the electrolysis line 3 • 10 Nm /h H2 from the reforming line • Purity of 99.999% minimum
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
The HyNor building and hydrogen station
HyNor Lillestrøm AS: R&D demonstration Projects • Hydrogen Production • Hydrogen Compression Akershus Energy AS: Research Projects • Renewable Energy
Hydrogen Electrolysis line Dispenser
Hydrogen Fuel Cell Vehicles
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
The reformer line
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
HyNor Lillestrøm R&D-building and H2-station
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
Sorption-Enhanced Steam Methane Reforming (SE-SMR) Principle and basic consept
H2-production with integrated CO2-capture in one single step
H2
NG Reactor 1 Reforming 600oC CaO Water
CaCO3 850oC Calcination CO2 Reactor 2
HEAT Ca. 1000oC
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
Sorption Enhanced Steam Methane Reforming Advantages of the novel H2-production route
• Higher H2-yields (95% +) than in conventional SMR, in one single step, and at lower temperature (500-600°C)
• Simplified process layout (fewer vessels)
• No need for shift catalyst
• Reduced needs for downstream H2-purification • Potential for lower production costs and energy savings
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
Reactor technology
• Fluidized bed reactor technology • Liquid like behaviour makes transport of solids possible • Very good heat transfer
• Dual bubbling fluidized bed reactor (DBFB) • 2 dedicated reactors connected with loop seals and transport riser • Continuous mode • Bubbling regime • Circulation rate regulated with a slide valve • High temperature tube heat exchanger in the regenerator
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
SE-SMR reactor technology developed at IFE Dual Bubbling Fluidized Bed (DBFB) reactor system Reformate
Top cyclone
CO2/steam
Hopper
Circulation valve Make-up solids tank REG cyclone (sorbent + catalyst)
REF cyclone
850 oC Exhaust gas Riser
HEXP-13 Regenerator Loop seal
o 600 C Burner exhaust gas
N2 Regenerator Loop-seal
Steam Purge tank N2 Reformer
Reformer feed
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
Simplified SE-SMR process
CO2 stream
Reformate gas Top cyclone
Make-up solids tank
Air 850oC Burner section
600oC Burner HT Bag filter Purge tank
Regenerator feed gas Reformer feed gas Reactor section
Hydrogen
Steam
Steam Exhaust gas
Upgraded biogas
Purification section Off-gas
Reformate Compressor buffer tank
Pd Sep. Sep. Membrane Pure hydrogen to compression Dryer
CO2 stream
Condensate Condensate
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
Experimental results R&D bubbling bed batch reformer/regenerator
Batch FB-reformer at IFE
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
The DBFB SE-SMR pilot
• H2 production capacity • 12.5 Nm3/h (before purification) • Reformer • 600oC; 0.5 barg max • 0.29 m/s; S/C ratio: 4 • Upgraded biogas (Swedish standard) • Regenerator • 850oC; 0.5 barg max • 0.10 m/s • Steam + 2 vol% hydrogen • Solids • Arctic dolomite from Franzefoss (Norway) • 200µm • Commercial reforming catalyst • 150µm • Ratio sorbent/catalyst: 2.5 – 3 w/w • Solids inventory: ca. 170 kg • Solids circulation rate: 75 kg/h
• Installation june-september 2012 • Testing and commissioning in last quarter of 2012
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
DBFB SE-SMR prototype
HT-HEX
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
DBFB SE-SMR prototype
Reformer freeboard Reformer
Freeboard seksjon Freeboard Reformer bed section bagfilter -
HT HT-HEX Loop-seal
Reformer windbox Riser bottom section
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
DBFB SE-SMR prototype
Reformer syklon
Regenerator freeboard Reformer
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
The regenerator HT heat exchanger
• 35 one-piece Outlet vertical U-tubes, ½” manifold • Inconel 601 • Tubes welded at both ends Inlet manifold HX top
HX housing
HX bottom
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
The regenerator HT heat exchanger Mechanical stress simulations
Inputs Units Value
Inlet HX gas temperature C 1050
Outlet HX gas temperature C 880
HX housing temperature C 850
Rupture life hours 1000
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
The regenerator HT heat exchanger Heat exchange calculations and CFD analysis
• Morelus et. al (1995) correlation considering combined gaseous and particle convection • Radiative heat transfer taken into account
C C
HT-HEX
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
The regenerator HT heat exchanger Temperature profile and gas distribution
HT-HEX
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
The catalytic burner (30 kWLHV)
Burner outlet
Air inlet
Fuel inlet
Diverse deler Diverse tanker
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
SE-SMR pilot at HyNor Lillestrøm H2-station
• Demonstrate «proof of concept» of SE-SMR in relevant pilot scale
• The SE-SMR pilot will be operated to gather experimental operation data for further development of the technology and upscaling towards industrial scale
• The SE-SMR pilot will be used as a technology platform for further development via R&D-projects • National projects financed by the Research Council of Norway • International collaborative projects through the EU FP7 program • Other international projects
• The SE-SMR pilot will be used as an «education tool» • PhDs, Post-Docs.
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
Forseen tests
• Test and optimation of the solids loop for • Maximum H2 yield • Maximum CO2 capture rate
• Test of the HT heat exchanger • Measurement of the overall heat transfer coefficient • Control of the mechanical structure • Investigate erosion problems
• Gather experimental particle attrition data
• Improve and validate models
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
See you next year for the results!
Thank you for your attention !
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
Other applications of the SE-SMR process Power production and co-production
• H2-production with CO2-capture and steam boilers
• H2-production with CO2-capture and CC power plant
• H2-production with CO2-capture and SOFC • ZEG-Power concept
• Co- production of electricity and hydrogen with
integrated CO2- capture • Electricity from high temperature solid oxide fuel cells (SOFC) • Hydrogen production by sorption enhanced steam methane reforming • High total energy efficiency
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
Heat exchangers
Divers heat exchangers
Air heat exchanger
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
Divers components
Regenerator cyclone
Top cyclone & compensator
HT-HEX
Regenerator grid
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
Divers tanks
Hopper tank & slide valve Solids tank
Purge tank
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012
Instruments and valves
4th IEA-GHG HTSLC network meeting, Beijing, 20-21 august 2012