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Solid Oxide Cell Enabled Ammonia Synthesis and Ammonia based Power Production
John Bøgild Hansen
Haldor Topsøe A/S 1
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We have been committed to catalytic process technology for more than 77 years
• Founded in 1940 by Dr. Haldor Topsøe • Revenue: 700 million Euros • 2400 employees • Headquarters in Denmark • Catalyst manufacture in Denmark and
the USA
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Topsoe ammonia plants Since 2000
Number of plants: 60 Accumulated capacity, MTPD: 99,505
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23
1 6
1 7
7 12
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Topsoe ammonia process – alternative with prereformer
Prereforming (optional)
Process cond. Ammonia
product
Purge gas
Stack
Process air
Natural gas
Process steam
Ammonia synthesis Methanation
CO2- removal
Desulphurisation Reforming
Shift
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SynCOR AmmoniaTM
Simplified process layout H
ydro
gena
tion
Sulfu
r rem
oval
Prer
efor
min
g
Aut
o th
erm
al
refo
rmin
g
Air
Natural gas + hydrogen
Fuel
Fired heater
Steam
Super heated steam
Hig
h te
mpe
ratu
re
shift
Hig
h te
mpe
ratu
re
shift
CO
2 rem
oval
Nitr
ogen
was
h
Sepa
rato
r
Process condensate
S-300
Ammonia conversion
Ammonia product
Nitrogen
CO2 Off gases Oxygen
Air separation unit
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Fuel Cell and Electrolyser
½O2
H2 H2O
½O2
H2O + 2e- → H2 + O2- O2-
O2- → 2e- +½O2
H2 + O2- → H2O + 2e- O2-
½O2 + 2e- → O2-
SOFC SOEC H2 H2O
H2 + CO + O2 H2O + CO2 + electric energy (∆G) + heat (T∆S) SOFC
SOEC
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SOEC more efficient than present Electrolysers Internal waste heat used to split water
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
0 100 200 300 400 500 600 700 800 900 1000
Deg C.
kWh
per N
m3
H2
Minimum Electricity Input
Waste heat which can be utilised to split water
Energy needed to evaporate water
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Biogas to SNG via SOEC and methanation of the CO2 in the biogas
Biogas
Oxygen
Water
Condensate
SNG
Steam Methanator
SOEC
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Biogas upgrading demonstration unit Operating in Foulum, Denmark
• 50 kW SOEC unit for steam electrolysis • Catalytic methanisation • The CO2 in the biogas is upgraded to pure
methane with pipeline quality. • High Exergy Efficiency of 80%
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SOEC Operating temperatures as function of voltage and ASR ASR = Area specific resistance
Source: O´Brien IMECE 2008
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Ammonia Synthesis Gas Generation by SOEC Efficiency = 77 % on exergy basis – 71 % on LHV basis
BFW Condensate
Steam
SOEC
Cooler
1
Recycle to SOEC
Syngas to NH3 loop
2 876543
Recycle to SOEC
Steam from NH3 loop
Air
SOEC SOEC SOEC SOEC SOEC SOEC SOEC
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Breakdown of power consumption in kWh per MT ammonia
6,785
154 20184
SOEC AirComp SyngasComp Refrigera4on
Totalenergy:7223kWh/MTNH3
Haber-BoschSynthesisonly6.0%!
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0
200
400
600
800
1000
1200
0 10 20 30Current in A
Cel
l vol
tage
in m
V
0.0
0.2
0.4
0.6
0.8
1.0
1.2
Pow
er d
ensi
ty in
Ω/c
m2
Hydrogen/nitrogen 3/1Ammonia
850 oC
Direct Ammonia SOFC
Same or better performance with ammonia as with H2+ N2 mixture 2 NH3 ⇒ 3 H2 + N2
0
200
400
600
800
1000
1200
0 5 10 15 20Current in A
Cel
l vol
tage
in m
V
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Pow
er d
ensi
ty in
Ω/c
m2
Hydrogen/nitrogen 3/1Ammonia
750 oC
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Direct use of Ammonia for SOFC
Flue gas
Air
AmmoniaSOFC
Anod
e
Cath
ode
CatalyticBurner
Expander
Electrical efficiency > 60 % LHV
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Conclusions
• Haldor Topsøe A/S has been the market leader for both catalyst and ammonia technology for decades
• Recently introduced process scheme enables capacities above 6000 MTPD capacity based on auto-thermal reforming of natural gas
• New Solid Oxide Electrolysis based synthesis gas process eliminates air separation unit and have very high efficiency
• Ammonia is the perfect fuel for Solid Oxide Fuel Cells without the need for water addition or fuel processing
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