Post on 31-Mar-2018
Status, progress and next steps of WP6
D E S I G N , D E V E L O P M E N T A N D T E S T O F
T H E P R O O F - O F - C O N C E P T P L A N T 1 ( I T A L Y : 2 k W C H P , W W T U B I O G A S )
SOFCOM Mid Term Review
SOFCOM WP6
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Key objectives of the DEMO in Torino (IT)
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The main general objective of SOFCOM DEMO unit in Torino (IT) is to demonstrate
the high interest of electrochemical systems based on high temperature fuel cells
to operate as the core of future energy systems with renewable fuels and
multi-product configuration, featuring also a CO2 recovery through re-utilization of
the C and H atoms inside the system using different processes (electrochemical,
chemical, biological as in SOFCOM).
DEMO 1 Torino (IT): field demonstration of WWTU biogas-fed SOFC with CO2
recovery and reuse; real operating environment.
The first proof-of-concept SOFC system is able to operate with biogas produced in
an industrial waste water treatment unit (WWTU). The plant will be in operation as
CHP plant, with heat recovery from the exhaust for the production of hot services
(hot water). Also, the plant will be completed with a with a section of CO2 recovery
for Carbon reutilization in a photo-bio-reactor for C storage in form of algae (CO2
sink).
DEMO: WWTU-SOFC-CO2 recovery: overall structure of the DEMO
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BIOGAS from SMAT digesters fed by secondary treatment sludges of the WWTP.Biogas:60% CH4 – 40% CO2
Two CLEANING VESSELS:• H2S removal
=> ZnO • Siloxanes removal
=> Activared Carbon• 14 SLPM biogas
FUEL PROCESSING UNIT• Steam reforming (demi
water from demineralizer)• Evaporator Mixer• Reformer (S/C = 2)• Reformer Temp. = 750 °C
SOFC Stack• 2 kWe• 90 cells, 3YSZ• SOFC Temp = 800 °C.• Inlet fuel Temp = 750 °C.• Inlet air Temp = 650 °C.
AIR PRE-HEATER• Inlet air pre-heated
through a mixed exhaust recuperator/electrical heater.
• Cathode exhaust used for CHP (water heating). CO2 SEPARATION UNIT
• Water condenser• Compressor up to 5 bar• Pressurized membrane
stage => H2O < 500 ppm
WASTE WATER TREATMENT VIA ALGAE GROWTH3 PBR modules (9 m2)Algae production 8 gdry/hOutlet streams: • Treated water (reduced N/P compounds)• Algae (to digesters)
POWER
HEAT
HEAT
ALGAE
DEMO: WWTU-SOFC-CO2 recovery: GANTT
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N TASK 15 18 21 24 27 30 33 36
6,1 Biogas production
6,2 Biogas cleaning system
6,3 Biogas processing system
6,4 SOFC CCHP system
6,5
O2 separation and anode
exhaust catalytic burner
6,6
CO2 separation from anode
exhaust
6,7
CO2 management and disposal
system
6,8 Testing of the complete system
6,9
Monitoring of the complete
system in the long run
YEAR 2 YEAR 3
PREVIOUS WORK UP TO M24
July 2013
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Detailed design of the demonstration plant.
August 2013
Deliverable 6.12 « Detailed blueprint of the demonstration of integrated system WWTU biogas + SOFC in Torino”
October 2013 SMAT: assignment of the installation and material/accessories supply to an external company
PLANT AREA (I)
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SMAT WWTU Plant, Torino (IT): serves over 2 million population equivalents in the metropolitan area of Torino treating over 620.000 cubic meters per day of waste water, with a production of 33000 Nm3/day biogas
PLANT AREA (III)
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Demonstration plant
Oxygen
Nitrogen
Carbon Dioxide
Hydrogen
Photobioreactor
Control Room
Shed
SOFCOM Demo Plant Units
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Cleaning Unit
Reforming Unit
SOFC Stack Unit
Oxy-combustor
CO2 separation Unit
Algae Water Treatment
CLEANING UNIT (I)
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Inlet biogas from SMAT max. 14 SLPM 100 ppm H2S 1100 ppb siloxanes
N2 for bed substitution 2 SLPM/month Clean biogas to
the reformer
CLEANING VESSELS
CLEANING UNIT (II)
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• Outside diameter 88 mm • Inside diameter 85 mm
• Height
1. ZnO: 30 cm 2. SiC: 5 cm 3. ZnO: 30 cm
• Particle size
• ZnO: 4.5 mm • SiC: 1.3 mm
Clariant catalyst ActiSorb S2 (G-72 D)
• Outside diameter 88 mm • Inside diameter 85 mm • Height
1. AC: 30 cm 2. SiC: 5 cm 3. AC: 30 cm
• Particle size: • AC: 4.5 mm • SiC: 1.3 mm
Norit RST3, steam activated carbn
H2S adsorber Siloxane adsorber
SOFCOM Demo Plant Units
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Cleaning Unit
Fuel Processing
SOFC Stack Unit
Oxy-combustor
CO2 separation Unit
Algae Water Treatment
FUEL PROCESSING (I)
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Reformate to SOFC stack
H2 for stand-by
N2 for start-up and stand-by
Demi water from Demineralizer + atmospheric tank (SMAT)
Biogas from cleaning
REFORMER
PUMP+PRESSURIZED TANK
To SOFC
To Reformer VENTING
FUEL PROCESSING (II)
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Mixed steam+dry reforming
Ni-based catalyst:
Commercial catalyst composed of 20wt% of Ni supported on -Al2O3 (63wt%) and CaO (5.5 wt%) mixture
Catalytic activity suffers the presence of sulfur compounds in the inlet gas stream (H2S conc. ≥0.4 ppm); while the presence of hydrocarbon compounds (conc. 200 ppm) and siloxane (D5 conc. <1 ppm) result less harmful.
0
20
40
60
80
100
0 20 40 60 80 100
CH
4C
on
ve
rsio
n (
%)
Time (h)
H2S = 2 ppm
H2 S= 1,6 ppm
H2S = 1 ppm
H2S = 0,4 ppm
H2S poisoned biogas steam reforming test (CH4/CO2=55/45%vol.) H2O/CH4=2 mol/mol; GHSV=10,000 h-1; T=1073K; p= 1bar
FUEL PROCESSING (III)
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Inlet connections for: • Biogas • Demi water • H2/N2
Evaporator mixer
Reformer
IN
OUT
FUEL PROCESSING (IV)
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Evaporator inlet
Reformer outlet
N2 and H2 MFC
Demi water MFC
Component/Unit Operation H2 [SLPM] N2 [SLPM]
Processing (CNR) Start-up/Shut-down 0.0 16.7
Stand-by 1.2 11.2
SOFCOM Demo Plant Units
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Cleaning Unit
Fuel Processing
SOFC Stack Unit
Oxy-combustor
CO2 separation Unit
Algae Water Treatment
SOFC STACK UNIT (I)
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N-H mix for Start-up and stand-by => N-H mix from the reformer MFC
Reformate
Cathode air
Tap water for CHP
Anode exhaust
Cathode exhaust
Tap water for CHP
SOFC
AIR PRE-HEATER
HX CHP
BLOWER
SOFC STACK UNIT (II)
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SUNFIRE® SOFC Stack 2 kWe 90 cells, 3YSZ SOFC working temperature = 800 °C. Inlet fuel temperature = 750 °C. Inlet air temperature = 650 °C.
Component/Unit Operation H2
[SLPM] N2
[SLPM]
SOFC Stack (POLITO) Start-up/Shut-down 3.0 57.0
Stand-by 20.1 30.1
SOFC STACK UNIT (III)
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DOMEL® Brushless blower for cathode air up to 300 mbar
FACO® CHP recuperator from cathode exhaust (340 - 90 °C)
SOFC UNIT (IV)
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SUNFIRE® Air recuperator (from ambient to 550°C). Air electrical heater (from 550 to 650°C).
Fixed connection between the SOFC stack and the air pre-heater Development of a common layout with reformer and oxy-combustor partners in order to avoid interferences.
SOFCOM Demo Plant Units
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Cleaning Unit
Fuel Processing
SOFC Stack Unit
Oxy-combustor
CO2 separation Unit
Algae Water Treatment
OXY-COMBUSTOR (I)
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Oxygen
Anode exhaust
Cooling air
Tap water for cooling
OXY-COMBUSTOR
Cooling air
Anode exhaust
Tap water for cooling
COOLER
A venting is inserted here
OXY-COMBUSTOR (II)
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oxy-combustor: operation in high temperatures, in range 700-800°C
ability to burn lean mixtures of gases composed mainly of H2 (15%max) CO (7%max), CO2, H2O
very efficient operation i.e. mole fraction of unburned H2 and CO < 0.2 %
pressure drop of the gases from SOFC stack on the burner should be lower than 20 mbar
silicon carbide (SiC) porous foam (porosity 0.86)
air-cooled
inlet oxgen from cylinders
water cooler at combustor outlet until 77°C.
OXY-COMBUSTOR (III)
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Porous SiC, layout 1
Porous SiC, layout 2
Catalytic oxy-combustor, water quenching required
OXY-COMBUSTOR (IV)
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3 layout developed by IEN, one still under testing The porous oxy-combustor (layout 1 and 2 have the same dimensions) has been chosen and used for the demonstration plant blueprint because: - It can be placed horizontal => Shorter connection pipe with the stack outlet.
- It does not require water quenching => Smaller amount of demi water from the
demineralizer.
Final hot-box layout
OXY-COMBUSTOR (V)
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Final hot-box layout
REFORMER
SOFC STACK
POROUS OXY-COMBUSTOR
AIR PRE-HEATER
Inlet and outlet connections from the stack will only require insulation due to short interconnection pipes. => NO electrical tracing
SOFCOM Demo Plant Units
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Cleaning Unit
Fuel Processing
SOFC Stack Unit
Oxy-combustor
CO2 separation Unit
Algae Water Treatment
CO2 SEPARATION (I)
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Anode exhaust
Air for the cooling fan
Tap water
CONDENSER
MEMBRANE
CMP
Tap water
CO2
CO2 SEPARATION (II)
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Condenser unit.
Compressor up to 8 bar.
Membrane separator (BEKO Technologies type 08-28A Drypoint M Plus) 100% CO2 (H2O 500 ppm)
with purge gas recirculation
MembranMembran
From Oxy-Combustor
Wet purge gas
Dry process gas
Needle valve for purge gas
adjustment
Mixing with purge gas
CO2 SEPARATION (III)
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Inlet connection
Compressor
Drypoint membrane
• Final check tests on November 2013 • Shipping to POLITO on Dicember 2013
SOFCOM Demo Plant Units
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Cleaning Unit
Fuel Processing
SOFC Stack Unit
Oxy-combustor
CO2 separation Unit
Algae Water Treatment
ALGAE WATER TREATMENT (I)
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CO2 - from the demo plant - from cylinder
Waste water
PBR
Treated water
Algae
TANK
MEMBRANE
ALGAE WATER TREATMENT (II)
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Inlet streams:
waste water (10 mg N/l + 1 mg P/l)
CO2 (dissolved concentration before inhibition 550 ppm)
Outlet streams: treated water, O2 and CO2 vented, algae purge.
Algae production: 20 g/m2/day (0.77 g/l/day)
EQUIPMENT LIST
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P&ID of the plant units
Equipment list with required items and supply partner
Auxiliary services definition and requirement calculation
Power Supply calculation
Control system definition
Demonstration plant layout drawing
AUXILIARY SERVICES (I)
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Nitrogen
N2 users: - Cleaning Unit (bed substitution – once a month) - Fuel Processor (start-up and stand-by) - SOFC (start-up and stand-by) => mixed with H2 in the
Processing Unit - Emergency
Parameter Max Nom Min
Total flow rate [NLPM] 57 30 2
Available temperature [°C] 30 20 10
Available pressure [barg] - 16 -
AUXILIARY SERVICES (II)
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Hydrogen
H2 users: - Fuel Processor (stand-by) - SOFC (start-up and stand-by) => mixed with N2 in the
Processing Unit
Parameter Max Nom Min
Total flow rate [NLPM] 20 20 0
Available temperature [°C] 30 20 10
Available pressure [barg] - 16 -
AUXILIARY SERVICES (III)
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O2 users: - Oxy-combustor (continuous flow rate during
operation)
Parameter Max Nom Min
Total flow rate [NLPM] 4.39 3.07 2.05
Available temperature [°C] 30 20 10
Available pressure [barg] - 16 -
Oxygen
AUXILIARY SERVICES (IV)
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CO2 users: - Photobioreactor (used when the demo plant is not feeding the
PBR).
Parameter Max Nom Min
Total flow rate [NLPM] - 0.0205 -
Available temperature [°C] 30 20 10
Available pressure [barg] - 16 -
Carbon dioxide
AUXILIARY SERVICES (V)
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Demi water Demi water users:
- Fuel Processor (continuous flow during reformer operation). Demi water stored in pressurized tank.
Parameter Max Nom Min
Total flow rate [NLPM] 0.715 0.715 -
Available temperature [°C] 30 20 10
Available pressure [barg] - - -
AUXILIARY SERVICES (VI)
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Tap water
Tap water users: - SOFC Unit (tap water for the CHP heat-exchanger) - Oxy-combustor (tap water used for exhaust cooling) - CO2 separation (tap water used in the condenser)
Parameter Max Nom Min
Total flow rate [NLPM] 1078 1078 -
Available temperature [°C] 30 20 10
Available pressure [barg] 3 2 1
AUXILIARY SERVICES (VII)
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Waste water
Waste water - Photobioreactor (continuous flow during PBR operation)
Parameter Max Nom Min
Total flow rate [NLPM] - 4.17 -
Available temperature [°C] 30 20 10
Available pressure [barg] 3 2 1
AUXILIARY SERVICES (VIII)
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Instrument air users: - Pneumatic Valves
Pressure = 4 barg Filtered and oil free (Max. oil content 0.003 ppm; max dust content 0.01 μm) Dehumidified (Dew point 20 °C max.)
Instrument air
CONTROL SYSTEM
47
Starting from the data about the control system related to each single unit (partner supply), the overall signals list with estimation of the un-completed issued concerning the control system and consequently the operation of the plant, has been made.
DEMO PLANT LAYOUT (I)
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Detailed sizing (IEN+POLITO) of the connection between oxy-combustor and cooler to reduce the stream temperature before the HX (AISI 304) => pipe length = 1 m
DEMO PLANT LAYOUT (II)
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Air pre-heater
Air CHP
Reformer
SOFC
Cleaning system
Oxy-combustor
Cooling
CO2 separation
FUTURE DEADLINES
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December 2013
• Demonstration plant installation
• Start-up of the first 3 units (Cleaning + Reformer + SOFC)
January 2014 • Installation and start-up of the
second 3 units (Oxy-combustor + CO2 separation +PBR)
March/August 2014 Start-up and operation period (6 month) of the overall demo plant
February 2014 • Complete assembly of the DEMO
DEMO: WWTU-SOFC-CO2 recovery: Deliverables
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Deliverable Number
Deliverable Title Lead benefi-ciary number
Estimated indicative person-months
Nature Dissemi-nation level
Delivery date
D6.1 Basic design for a biogas cleaning system for a first proof-of-concept SOFC system in Torino
2 1 R PU M18
D6.2 Installation and operation of the biogas production system
4 20 D RE M21
D6.3 Installation and operation of the biogas cleaning system
2 1 D RE M21
D6.4 Installation and operation of the biogas processing system
6 10 D RE M21
D6.5 Installation and operation of the SOFC CCHP system
1 30 D RE M21
D6.6 Installation and operation of the O2 separation and anode exhaust catalytic burner
7 2 D RE M24
D6.7 Installation and operation of the CO2 separation from anode exhaust
9 1 D RE M24
D6.8 Installation and operation of the CO2 management and disposal system
5 10 D RE M24
D6.9 Analysis of the specific test session on the complete system
1 27 R PU M33
D6.10 Analysis of the monitoring on the complete system on the long run
1 21 R PU M36
D6.11 Analysis of all the repair and maintenance activities developed on the complete system
4 26.5 R PU M36
Total 149.5