Solar Fuels Research at CSIRO - Indian Institute of ...iitj.ac.in/CSP/material/20dec/fuels.pdf ·...

Solar Fuels Research at CSIRO Dr Jim Hinkley| Senior Research Scientist, Solar Thermal

December 20, 2013

CSIRO ENERGY TECHNOLOGY

Overview Australia, CSIRO

Background Current cost of CSP

Cost saving potential

CSIRO Facilities / Research Activities Solar Air Turbine

Advanced Steam Generating Receivers

Advanced Solar Thermal Energy Storage

CSP & CCS

Solar Fuels

SolarGas India Study

Concentrating Solar Thermal Research at CSIRO| Jim Hinkley |

CSIRO – Australia´s National Science Agency CSIRO is the Commonwealth Scientific and Industrial Research Organisation 70% funded by Federal government

One of the largest and most diverse research organisations in the world

Established 1926, 6 300 people, 57 sites

Research co-ordinated through both divisional (reporting structure) and flagships (research priorities)

Divisions: Astronomy and Space, Energy, Environment, Farming and Food, Health and Wellbeing, Information & Communication Technology, Manufacturing, Materials, Mining & Minerals, Transport & Infrastructure.

More information: www.csiro.au


http://www.csiro.au/

Australia

Australia is very big, very sunny, and rather empty...

One of the best places in the world for solar, but • Relatively little installed

other than rooftop PV and solar hot water

• Some demonstration projects (Liddell, Kogan Creek hybrid)

• Coal is cheap & plentiful

• CSIRO Energy Technology working hard to develop solar technologies


Source: “Australian Energy Resource Assessment.” 1 March 2010.

Geoscience Australia and ABARE

The age of CSP is arriving: ~3 GW globally (mainly troughs…)


Reported LCOE from various studies for projected trough and tower plants in 2010 $AU.

0

100

200

300

400

500

600

700

800

[16] Turchi et al

(2010)

[18] EPRI (2010)

[19] Hearps &

McConnell (2011)

[20] Hinkley et al

(2011)

[16] Turchi et al

(2010)

[18] EPRI (2010)

[20] Hinkley et al

(2011)

LC

OE

($

/MW

h)

Trough Tower


Current status of CSP – Levelised Cost of Electricity (LCOE) in Australia

wind coal

PV

annual O&M costs 23%

annual financing

& insurance

costs 77%

Dominated by capital rather than O&M costs ($4500/kW) 2005 EU study: costs for a power tower system (5 x 11 MW)

Cost of electricity = 27 c/kWh (0.17 €/kWh)

Cost of CSP... Power tower

Prepared from data in:

Pitz-Paal et al, ECOSTAR (European Concentrated Solar Thermal Road-

Mapping), Roadmap Document, 2005, DLR (EU FP-6 project)

solar f ield39%

receiver13%

tower5%

storage4%

power block20%

land 2%

indirect costs 17%

Capital Breakdown Levelised Costs


T = 1200°C

= 25 % (annual)

Decrease costs through...

Plant efficiency (field size)...

T = 600°C

= 16 %

(annual)


Opportunities to Increase Plant Efficiency

Energy flow diagram for a power tower CSP plant Source – Hinkley et al (2011)

10.7%

40.1%

2.84%

2.78%2.04%

0.34%

24.7%1.9%

14.58%

100%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

SOLAR RESOURCE

OPERA-TIONAL

OPTICAL SPILLAGE RECEIVER ABSORP

LOSS

RECEIVER THERMAL

LOSS

STRORAGE & HTF LOSS

CYCLE HEAT

REJECTION

PARASITIC LOSS

NET OUTPUT

Incident solar radiation

Solar energy (light)

Thermal energy (heat)

Electrical energy (power)


Mainly

geometric

Power cycle

efficiency

by increasing HTF and power cycle temp...

Estimated LCOE for “current generation” troughs and tower for

varying HTF peak temperatures. Source – Hinkley et al (2011)

100

150

200

250

300

350

400

300 400 500 600 700 800 900 1000

LC

OE

, $/M

Wh

Upper Temperature of HTF, C

LCOE Towers

LCOE Troughs

Min: $170

680 C

Min: $158

880 C


Diminishing returns

(trade-offs)

Higher conc. ratio

of towers means

lower re-radiation

losses

Optimum beyond

current HTFs

oil salt

target

… while also reducing capital cost

Cost Saving Opportunities CSIRO Research Challenge

Power block and heliostat economies

of scale

Low cost and high performance

heliostats, small modular MW (5-

10MW) technologies matched to

markets for early deployment

Technical maturity – component and

ongoing costs

Low maintenance heliostats,

improved reliability of components

Increased plant efficiency Higher temperature, higher solar

concentration ratios, improved optical

performance, higher receiver

efficiency, higher temperature storage

media


Concentrating solar thermal research at CSIRO


Section 2:

Targeted portfolio of CSP Research Activities

CSP technology

portfolio

CSIRO Heliostat and Receiver Technologies

Research funding typically a mix of funding sources

e.g., CSIRO 40%, ARENA (ASI) 40%, Industry 20%

Steam

Steam turbine

Process heat

Electricity

Thermal Storage

Targeted portfolio of CSP Research Activities

CSP technology

portfolio

CSIRO Heliostat and Receiver Technologies

Subcritical or

Supercritical

Hydrogen production for industrial applications

Liquid transport fuels via Fischer Tropsch or Methanol

Electricity

Shift Reactor

Solar

Reforming

Syngas

Gas turbine – simple or combined cycle

Air

s-CO2 Electricity s-CO2 Brayton Cycle

Air/CO2 receivers

CSIRO’s solar thermal research facilities

Solar Field 1

Aerial view: 9 April 2011

Solar Field 2


500 kWth 1200 kWth

Heliostat Development

• CSIRO has developed its own heliostat

technology including the heliostat design and all

control systems.

• Work ongoing since 2006 follow poor offerings

from market

• Reliable, precise, high concentration solution


0

100

200

300

400

500

600

700

800

ECOSTAR CSIRO Company X

Company Y

He

liost

at c

ost

$/m

2

CSIRO Company

Y Company

X


High Performance Low Cost Heliostats

CSIRO Heliostat

Control Screen

Calibration Image Heliostat Electronics


Ray Tracing developed from surface mapping of heliostat surface

Annual energy delivery


Solar Air Turbine Project Duration: 2 years, 8 months from Sept 2010

Budget: $10.6M (incl. 1.2 MWth field, tower)

Funding: $5M ASI Foundation Project

Major Works:

• 600kWth receiver test

• Demonstration of air turbine

• Development of designs for 2MWe and pre-

commercial 5-10MWe plants

Participants:

CSIRO and Mitsubishi Heavy Industries (MHI)

Achievements:

• Air heated to 850°C (world record)

• Non-delivery of turbine ex Israel*

• Alternative turbine sourced & commissioned


*Alison 250 helicopter engine, used in the SOLGATE project, alterations by ORMAT

Solar Brayton Systems

Scalable from micro-turbines up to large gas turbines

Distributed generation option for CSP

Spinning mass reduces the impact of transient output

Can be co-fired with supplementary energy source such as natural gas providing high availability

Only inputs required are air and sun

Low water requirement (heliostats)

Large capacities can be met by clustering individual units

1 2

3

4

1

3

4


Advanced Steam Project

Advanced Steam-Generating Receivers for High-Concentration Solar Collectors

Duration: 3½ years from January 2010

Budget: $9.695M (ASI $2.8M)

ASI Project, now administered by ARENA

Major Works:

• Steam receivers to match highest efficiency commercial turbines

• Superheated steam receivers

• Modelling of solar steam systems

• Hybrid steam/thermoelectric receivers

Participants – CSIRO, Abengoa


Advanced Steam Project

Status: steam production demonstrated

• 540 C, 5 Mpa 17 MPa


Decoupling High Temperature solar energy collection and steam generation


: Ceramic,

ASI Advanced Solar Thermal Energy Storage

Duration: 3 years commencing January 2010


Major Works:

• Construction and operation of solar thermal storage, receiver and heat recovery systems

• Storage of thermal energy at temperatures above 700 C

• Development of new materials for HTF / TES (salts)

• Higher energy density / lower inventory

• Suitable for low temperature reforming

Participants – CSIRO, Abengoa


CCS and CST


Evaluation and demonstration of hybridisation of concentrated solar

thermal (CST) technology with carbon capture and storage (CCS).

Duration: 2 years commencing July 2012


Major Works:

• Modelling of integration options

• Construction of a trough loop at an operating plant (Vales Point)

• Evaluate performance - integrate with existing CCS pilot plant

• Techno-economic evaluation

Participants – CSIRO, Delta Electricity

Solar Hybrid Fuels Project


Duration: 3.5 years commencing July 2012


Major Works:

• Design, construction and operation of low temperature (membrane based) reforming reactor

• Development of new bifunctional, low temperature catalysts

• Development of a solar hybrid fuels roadmap with experts and stakeholders

Participants

• CSIRO, Orica, CSM, Chevron

• Niigata University (Japan), DLR (Germany), Arizona State University (US), ETH Zurich, Paul Scherer Institut (Switzerland), Alberta Innovates Technology Futures (Canada), SolarPACES task II

Building on SolarGas project (solar steam reforming of methane)

Solar Fuels


Section 3:

Renewable energy = electricity?


Renewable technology blind spot

Energy use in Australia

by sector, 2008-09

Main fuel per sector

Source: ABARES

Energy update 2011


Solar Hybrid Fuels

Australia is facing a large difference between liquid transport fuel consumption and domestic production

Projected deficit to increase from $13b in 2010 to $70b by 2030

Australia has world class solar and natural gas resources

10

20

30

40

50

60

70

80

2009-10 2019-20 2029-30

Re

al 2

00

9-1

0 A

$ b

illio

n


Resource overlap – solar/gas

Sources:

Geoscience

Australia


Solar Fuels - CSIRO’s Solar H2 Technology “Transitional and modular - bridging the gap to sustainable hydrogen”

Natural gas & water

Concentrated solar energy SolarGas (26% Solar Energy)

SolarGas India Study| Australian High Commission, New Delhi | 16 Dec 2013

The concept

Fossil

Fuel (CH4)

Water

water

CO/H2/CO2 H2/CO2 H2 - fuel

CO2 to disposal /

sequestration

• Fuel cells

• Gas turbines

• Cogeneration etc

CH4 + H2O(l ) + 250 kJ CO + 3H2

CO + H2O(l ) H2 + CO2 + 3 KJ

Solar

Thermal

Fuel

Reforming

Solar Thermal

Water Gas

Shift

Conversion

CO2

Recovery

Advanced

Power

Generation ~

High temperature solar steam and SolarGas ™

Solar reactor or solar boiler

Solar steam

SolarGas

Shift reactor

High temperature solar steam and SolarGas ™

Solar reactor or solar boiler

Solar steam

SolarGas

Shift reactor

Gas combined cycle

power generation

Liquid transport

fuels via

methanol or

Fischer Tropsch

Hydrogen

Solar Hybrid Fuels / Solar GTL

NG reforming requires a lot of thermal energy (heat)

Conventional approach: burn some of NG

SolarGasTM uses solar energy to provide this thermal input

Embody solar energy in chemical bonds

Reduce carbon intensity of syngas production

Adding on GTL step could provide liquid fuel with reduced GHG intensity, produced using Australian resources

Options include FT for diesel, methanol and MTG


Solar reforming & GTL


1997-2002 Successful solar reforming - earlier work

CSIRO has been studying solar reforming >15 years

Today (Newcastle)

WATER PRODUCT

GAS

SOLAR ENERGY

NATURAL GAS

CSIRO Solar cavity receiver – process schematic

Tube in Tube Directly

Irradiated Receiver Reactor


SolarGasTM Prototype Reactor

Thermal capacity 250kWth

NG feed rate 20 kg/hr

Catalyst Al2O3- and MgAl2O4- based commercial catalysts

Operating temperature 800°C

Steam to carbon ratio 3.5:1

SolarGasTM composition (vol%) H2 (68.6%), CO (12.6%), CO2(8.9%), CH4(9.9%)

Solar Energy Added to NG Feed


Energy increase in product gas vs bed temperature

vs. conventional reforming:

-30% (burning NG)

~1.5 to 2 x syngas energy

from same feed (CO2)

Stable process


0

20

40

60

80

11:00:00 AM 11:30:00 AM 12:00:00 PM 12:30:00 PM 1:00:00 PM 1:30:00 PM

Time of Day

Pro

du

ct

Ga

se

s(%

Vo

l);

C

H4 C

on

ve

rso

n %

0

200

400

600

800

1000

Cata

lyst

Bed

Exit

Tem

pera

ture

Hydrogen Production

Catalyst Bed Temperatures

Carbon Dioxide

Carbon Monoxide

Methane

Reforming with catalyst bed temperature in reactor of 760°C showing high levels of

hydrogen production and process stability

Performance

Reactor performance vs time of day showing conversion efficiency at 95% of equilibrium

50

60

70

80

90

100

12:00:00 PM 12:30:00 PM 1:00:00 PM 1:30:00 PM 2:00:00 PM 2:30:00 PM 3:00:00 PM

Time

Co

nv

ers

ion

/ P

erf

orm

an

ce (

%) Theoretical Conversion

Experimental Conversion

Performance (% of Theoretical achieved)

Process Energy Flows (H20:CH4 ratio)


input calculated input calculated

Basic Condition Basic Condition

Solar Field Eff. 80 % Solar Field Eff. 80 %

Spillage 5 % Spillage 5 %

Aperture Dia 600 mm Aperture Dia 600 mm

T for radiation clc. 810 oC T for radiation clc. 810 oC

Conv./Cond. Loss 8 % Conv./Cond. Loss 8 %

H2O/CH4 ratio 3.5 H2O/CH4 ratio 1

Conversion Rate 81.8 % Conversion Rate 81.8 %

Sun Sun

220 kW 220 kW

Heliostat Field overall field loss Heliostat Field overall field loss

44.0 kW 44.0 kW

176 kW 176 kW

spillage spillage

167 kW 8.8 kW 167 kW 8.8 kW

Receiver radiation loss Receiver radiation loss

Reactor 21.9 kW Reactor 21.9 kW

(including conv./cond. loss (including conv./cond. loss

heat recovery) 13.4 kW heat recovery) 13.4 kW

CH4 inlet CH4 inlet

0.442 mol/sec 0.744 mol/sec

25.4 kg/hr 42.8 kg/hr

485 kW 353 kW, LHV 727 kW 595 kW, LHV

Condenser latent heat Condenser latent heat

48.1 kW 5.5 kW

sensible heat sensible heat

9.4 kW 1.1 kW

Solar Gas 428 kW, LHV Solar Gas 720 kW, LHV

Solar in Chemical 74 kW, LHV Solar in Chemical 125 kW, LHV

Upgrad Ratio 21 % Upgrad Ratio 21 %

Solar to Chemical 34 % Solar to Chemical 57 %

Solar Efficiency Summary Solar Efficiency Summary

Field Eff. 80 % Field Eff. 80 %

Through Aperture 95 % Through Aperture 95 %

Receiver Eff. 79 % Receiver Eff. 79 %

Through Condenser 56 % Through Condenser 95 %

Overall S to C 34 % Overall S to C 57 %

Today (3.5:1) Target (1:1)

input calculated input calculated

Basic Condition Basic Condition

Solar Field Eff. 80 % Solar Field Eff. 80 %

Spillage 5 % Spillage 5 %

Aperture Dia 600 mm Aperture Dia 600 mm

T for radiation clc. 810 oC T for radiation clc. 810 oC

Conv./Cond. Loss 8 % Conv./Cond. Loss 8 %

H2O/CH4 ratio 3.5 H2O/CH4 ratio 1

Conversion Rate 81.8 % Conversion Rate 81.8 %

Sun Sun

220 kW 220 kW

Heliostat Field overall field loss Heliostat Field overall field loss

44.0 kW 44.0 kW

176 kW 176 kW

spillage spillage

167 kW 8.8 kW 167 kW 8.8 kW

Receiver radiation loss Receiver radiation loss

Reactor 21.9 kW Reactor 21.9 kW

(including conv./cond. loss (including conv./cond. loss

heat recovery) 13.4 kW heat recovery) 13.4 kW

CH4 inlet CH4 inlet

0.442 mol/sec 0.744 mol/sec

25.4 kg/hr 42.8 kg/hr

485 kW 353 kW, LHV 727 kW 595 kW, LHV

Condenser latent heat Condenser latent heat

48.1 kW 5.5 kW

sensible heat sensible heat

9.4 kW 1.1 kW

Solar Gas 428 kW, LHV Solar Gas 720 kW, LHV

Solar in Chemical 74 kW, LHV Solar in Chemical 125 kW, LHV

Upgrad Ratio 21 % Upgrad Ratio 21 %

Solar to Chemical 34 % Solar to Chemical 57 %

Solar Efficiency Summary Solar Efficiency Summary

Field Eff. 80 % Field Eff. 80 %

Through Aperture 95 % Through Aperture 95 %

Receiver Eff. 79 % Receiver Eff. 79 %

Through Condenser 56 % Through Condenser 95 %

Overall S to C 34 % Overall S to C 57 %

SolarGasTM India Study

Section 4:


Goals & Participants

• Study funded by Australian Government (DFAT/AusAID)

• SECI counterpart organisation to CSIRO

• Aims: • Assessment of solar resource and industrial opportunities for H2

• Develop design and localised costs for pilot scale plant in India

• Approach

• Kick off meeting and stakeholder workshop hosted by SECI April 2013

• Engineering component by Hatch – RSA and India, co-ordinated Au

• CSIRO project lead, assisted by IT Power in review role


Potential sites

Northern Indus

Basin

Cambay Basin Assam Basin

Bengal Basin

Mediyan Basin

Oil Refinery

Fertilizer Plant

Natural gas basins

NG pipeline


Hatch concept design

Proposed SolarGasTM Pilot Plant in India

Hatch predicted operational parameters

Design point solar input 1086 kWth

NG feed rate 163 kg/hr

Reactor NG conversion 81.8%

Operating temperature 750°C

Steam to carbon ratio 2.5:1

SolarGasTM composition (vol%) H2 (68.6%), CO (12.6%), CO2(8.9%), CH4(9.9%)

Inlet energy NG 2107 kW

SolarGas outlet energy 2435 kW

Annual SolarGas production 881 tonnes

The Business Case (effect of NG price)


Benefits of SolarGas in India

The technology is well suited to local deployment leading to job creation through the local manufacturing and operation of the technology.

The technology could provide improved energy and food security through reduced consumption of natural gas for the production of hydrogen and reduced risk to future increase in natural gas costs

– The consumption of less natural gas per unit of hydrogen produced enables greater yields of fertilizer from existing natural gas infrastructure, and reduces carbon emissions.

– The potential for lower cost hydrogen production could lead to lower cost fertilizer for the agricultural sector by reducing feedstock costs.

The technology could reduce hydrogen production costs for other users such as petrochemical companies

Gujarat and Rajasthan were identified as key states for the application of the technology due to excellent solar resource, existing natural gas infrastructure and existing major industrial users of hydrogen in the petrochemical and fertilizer industries.

Conclusions

Renewable energy has largely meant renewable electricity Doesn’t address most of primary energy demand

Solar fuels / solar hydrogen could address some of these needs Solar fossil hybrids to make conventional fuels

Solar hydrogen as a fuel and low emission feedstock for fertilisers/petrochem

CSIRO has significant expertise:

Low cost, high performance heliostats

Receiver development

SolarGas technology ready for demonstration and deployment

India has many favourable factors for early market deployment


Thank you

ENERGY TECHNOLOGY

Energy Technology Dr Jim Hinkley Senior Research Scientist

t +61 2 4960 6000 e [email protected] w www.csiro.au/energy

Solar Fuels Research at CSIRO - Indian Institute of ...iitj.ac.in/CSP/material/20dec/fuels.pdf ·...

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