Fcto Webinarslides Highly Efficient Solar Tc Reaction Systems 011315

7/25/2019 Fcto Webinarslides Highly Efficient Solar Tc Reaction Systems 011315

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1 | Fuel Cell Technologies Office eere.energy.gov

Highly Efficient, Solar Thermochemical Reaction

Systems (2014 R&D 100 Award Winner)

U.S. Department of Energy

Fuel Cell Technologies Office


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Question and Answer

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HIGHLY EFFICIENT, SOLARTHERMOCHEMICAL REACTION SYSTEMS

Robert S Wegeng, PI

FCTO Webinar

2014 R&D 100 Award Winning Technology

January 13, 2015


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Robert S Wegeng, PI

FCTO Webinar January 13, 2015

Acknowledgments

To the DOE Fuel Cell Technology Office (FCTO)for

early support in the 1990s and 2000s to the micro- andmeso-channel process technology that is being

adapted for solar applications!

To the DOE Solar Energy Technologies Officefor thesupport to the current work that is being described in

this presentation!

To FCTOfor the opportunity to present our work in thiswebinar!

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Robert S Wegeng, PI

FCTO Webinar January 13, 2015

Project Team

Pacific Northwest National Laboratory

Southern California Gas Company

Diver Solar LLC

Barr Engineering

Infinia Technology Corporation

Oregon State University

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Solar Thermochemical Reaction SystemOn-Sun Testing Accomplished 69% Solar-to-Chemical EnergyConversion Efficiency* During 2013

Technology Readiness Level 4 (TRL 4) Reaction System

* Solar-to-Chemical Energy Conversion Efficiency is defined as the ratio of theincrease in the Higher Heating Value (HHV) in the reacting stream to the direct(non-diffuse) solar energy that is incident upon the parabolic dish concentrator.

Solar Nacelle

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Technical ApproachUse Concentrated Solar Power to Augment the Chemical EnergyContent of Methane and Produce Syngas

ThermochemicalReaction System

RadiantEnergy

Concentrated Solar Energy

Methane Steam Reforming:CH4+ H2OCO + 3H2

Synthesis Gas exiting the Solar Thermochemical

Reaction System has about 25-28% greater chemical

energy than the incoming methane stream

Electrical Power

Transportation Fuels

and Other Chemicals

Electrical powergeneration at lessthan 6 /kWh

Hydrogen productionat less than $2/gge7


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Outline

Introduction and Summary

Concentrating Solar Power Examples

Previous Solar Thermochemical Processing Efforts

Example Applications

Micro- and Meso-Channel Process Technology

TRL 4 System Performance

TRL 5 System Discussion (including preliminaryperformance data)

Plan for TRL 6 DemonstrationConclusions

Recent Selected References

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Concentrating Solar Power

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Concentrating Solar PowerWorlds Largest Solar Thermal Power Station: Ivanpah

Californias Mojave Desert 392 MegaWatts 173,500 heliostats, each

with two mirrors

Developed byBrightSource Energy

and Bechtel Unit 1 connected to the

grid in September 2013 Capital Cost: $2.2 B Largest investor: NRG

Energy

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Previous Work by OthersSolar-to-Chemical Energy Conversion

Sandia 1980s

Experiments consisting of the solarCO2reforming of methane In conjunction with the Weizmann

Institute of Science, using a heat pipesolar receiver and integrated reforming

reactors In a direct catalytic absorption reactor;

with a 3.5 kWssolar concentrator

Weizmann Institute of Science andDLR 2000s

Solar steam reforming of methane;400 kWs

Sandia and DLR 1990s

Solar CO2reforming of methane;150 kWsconcentrator; chemicalefficiency of 54%

DLR and CIEMAT 1990s

Solar steam reforming ofmethane; 170 kWs

DOE Hydrogen Program

Several solar thermochemical

water-splittinginvestigations Requires significantly higher

temperatures, advanced materials,innovative thermal recuperationmethods

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Solar CO2-Methane ReformingDemonstration (~1990-1993)Photo courtesy of Sandia National Laboratory

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Applications of Solar Methane ReformingPower Generation via Combustion Turbine

Efficient conversion ofsolar energy to electricity

High capacity factors(>90%)

Reduced CO2emissions

Competitive LevelizedCost of Electricity(LCOE); acceleratedapproach to grid parity

for Concentrating SolarPower (CSP)

Net Solar Thermochemical Reaction

CH4+ H2O CO + 3H2

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Applications of Solar Methane ReformingH2Production

Requires components inaddition to solar reformingsystem, already indevelopment or proven

Projected H2productioncost: < $2/gge (gallons of

gasoline equivalent)based on H2A andstandard assumptions

Projected carbonemissions as low as 5.5kg CO2/kg H2; orapproximately ofconventional H2production via methanereforming

Potential commercialpractice by 2020

Net Reaction:

CH4+ 2H2O CO2+ 4H2

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750-800C

410-275C


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Applications of Solar Methane ReformingProduction of Solar Methanol for Renewable (Thermochemical)Energy Storage

Methanol is a commodity chemical, soldworldwide (100 million metric tons)

CO2in the product stream can in principlebe recycled, yielding high overall selectivityto CH3OH

Process enables inexpensive

thermochemical energy storage forconcentrated solar and other renewableenergy

Using solar energy to run endothermicoperations avoids carbon emissionsassociated with methanol production(typically 25-40% of incoming carbon isemitted as CO2)

Low-carbon intensity (based on lifecycle)methanol could also be used for otherpurposes. For example, as an additive togasoline to help states meet Low CarbonFuel Standards (LCFS)

Net Reaction:

CH4+ H2O CH3OH + H2

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300-175C15+ bar


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Core Technology/CompetitiveAdvantageMicro- and Meso-channel Reactors and Heat Exchangers

In development at PNNLsince mid-1990s

Compact

Process-Intensive

Exploit rapid heat andmass transport in thin,engineered channels

Exploit economies of

mass production (asopposed to classicaleconomies of scale forchemical processtechnology)

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Core Technology/Competitive AdvantageSeveral prototype reactors and heat exchangers for H2production weredeveloped during FY1997-2003 with Hydrogen Program Funding

Modular, process-intensive reactors and heat exchangers yield highly efficient systems

1999 Recipient ofR&D 100 Award

Exergetic Efficiency: 85.0

==

InExergy

OutExergy

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Reactor Test System Process Flow Diagram

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REACTOR/RECEIVER

HTR

3.15 kW

LTR-M

219 W

LTR-W

864W

EV

(3.27 kW)

HPLC PUMP

MCF3 MFC2 MFC1

CH4

120 SLM

N2 5%H2/N2

DI-H2O

BPR-1

LTHX~2.0 kW

GAS LIQUID SEPARATOR

WATER DISCHARGE

TO FLARE

GC SAMPLING

SOLAR

10 kW

ON-DISH HEAT DRIVE BOUNDARY

DISH CONCENTRATOR

Solar Nacelle

Parabolic DishConcentrator

Reactor/Receiver

HX Network


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On-Sun Reactor Tests in 2013World Record Solar-to-Chemical Energy Conversion Efficiency: 69.6%

Energy absorption with different solar screens implies 2 kWtfixedheat loss

High solar-to-chemical efficiency over a wide range of operatingtemperatures and DNI; believed to be a world record

0

5

10

0 5 10 15

Reactor

HeatDuty(kW)

Receiver Energy Input (kW)

No Screen

0.44 Screen

0.66 Screen

0.80 Screen

Linear Fit

2.0 kW

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SunShot Project DescriptionThermochemical System Evolution

TRL 3 Reactor / HXR

63%

TRL 4 Reactor / HXR

69%

TRL 5 Reaction System

Designed for 70+%Initial Testing Oct 201420


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TRL 5 Solar Thermochemical ReactorDesign, Fabricate and Assemble

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TRL 5 Reactor Progress

Nickel-coated front plate with catalyst inserts (right-of-center).Front plate after bonding (two left images). Hermetic testing (right).


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TRL 5 Solar Thermochemical ReactionSystem AssemblyHeat Exchanger Network

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Exergy Conversion and DestructionCalculations from Phase 1 (TRL 4 System)


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TRL 5 Solar Thermochemical ReactionSystem AssemblyWithin Nacelle

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Test SitesRichland, Washington (PNNL)Brawley, California (San Diego State University)

Pacific NorthwestNational LaboratoryConvenient access tonational laboratory

Annual Average SolarResource: ~5 kWh/m2/day

Summer testing isenhanced by long days

Winter months arehampered by cloud cover

San Diego StateUniversity Branch

CampusAnnual Average SolarResource: 7-8 kWh/m2/day

High testing productivityyear-round

Support from SouthernCalifornia Gas Company

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Richland Brawley


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Concentrator Setup and Calibration

Moon Tests

Cold Water CalorimeterSetup of Concentrator Test Stand

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TRL 5 Solar Thermochemical ReactionSystem AssemblyPrep for On-Sun Testing

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On-Sun Reactor Tests in 2014Increase in Solar-to-Chemical Energy Conversion Efficiency Expectedin 2015

Fixed heat loss reduced to ~1 kWt High solar-to-chemical efficiency in the mid-70%s at higher

DNIs; expected to be confirmed with testing at Brawley test site in2015

0 200 400 600 800

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

0 2 4 6 8 10 12

Normalized DNI (W/m2)

SOLARTOCHEMICALEFFICIENCY

(kWHHV/

kWsolar)

RECEIVER POWER INPUT (kWsolar)

TRL5 (2014)

TRL4 (2013)

1.0 kW

0 200 400 600 800 1000

0

1

2

3

4

5

6

7

8

9

10

0 5 10 15

Normalized DNI (W/m2)

REACTORHEAT

DUTY(kW

H

)

RECEIVER POWER INPUT (kWsolar)

TRL5 (2014)

TRL4 (2013)

2.0 kW

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Plan for SunShot Project, Phase 3During CY2015

Advance Solar Thermochemical Reaction Systemto TRL 6

Target solar-to-chemical energy conversion efficiency:74-75%

End-to-End Demonstration with Electrical PowerGeneration

Continued Evaluation of Manufacturing Methods

and Technoeconomics

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Conclusions

Highly Efficient Operation: High solar-to-chemical energy efficiencieshave been demonstrated in on-sun tests

~70% in 2013 and 2014

Expect mid-70%s in CY 2015

Values exceeding 80% are feasible

Process Intensive, Micro- and Meso-channel Reactors and HeatExchangers

Originally developed in DOE Hydrogen Program

Now being adapted to utilize concentrated solar energy

Reasonable Costs Expected

Strong advantage through economies of hardware mass productionNear-Term Applications Anticipated:

Electrical power generation at ~6 /kWh (LCOE)

H2production at


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Acknowledgments

US Department of Energy Solar Energy Technologies ProgramProgram Managers and Staff

US Department of Energy Fuel Cell Technology OfficeInitial funding of microchannel reactors and heat exchangers (circa 1996-2003)

Project Team

Pacific Northwest National Laboratory

Southern California Gas Company

Diver Solar LLC

Barr Engineering

Infinia Technology Corporation

Oregon State University

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Our Team


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Our TeamIntegrated Solar Thermochemical Reaction System

Robert Wegeng (PI, Project Manager)

Daryl Brown, Dustin Caldwell, Rick CameronRichard Diver (Diver Solar), Rob Dagle, Brad Fritz, Paul HumbleDan Palo (Barr Engineering), Ward TeGrotenuis, Richard Zheng

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Questions?

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Recent Selected References

Zheng, R and Wegeng, R, Integrated Solar Thermochemical Reaction System forSteam Methane Reforming, 2014 SolarPACES Conference, Sep 2014.

Brown, D, TeGrotenhuis, W and Wegeng, R, Solar Powered Steam-MethaneReformer Economics, Energy Procedia, June, 2014.

Wegeng, R, Diver, R and Humble, P, Second Law Analysis of a Solar MethaneReforming System, Energy Procedia, June, 2014.

Wegeng, R, Brown, D, Dagle, R, Humble, P, Lizarazo-Adarme, J, TeGrotenhuis, W,Mankins, J, Diver, R, Palo, D, Paul, B, Hybrid Solar/Natural Gas Power System, 2013International Energy Conversion Engineering Conference, July, 2013.

Wegeng, R, D Palo, R Dagle, P Humble, J Lizarazo-Adarme, S Krishnan, S Leith, CPestak, S Qiu, B Boler, J Modrell and G McFadden, Development and Demonstrationof a Prototype Solar Methane Reforming System for Thermochemical Energy Storage

Including Preliminary Shakedown Testing Result, 2011 International EnergyConversion Engineering Conference, July 2011.Humble, P, D Palo, R Dagle and . Wegeng, Solar Receiver Model for an InnovativeHybrid Solar-Gas Power Generation Cycle, 2010 International Energy ConversionEngineering Conference, 2010.

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Thank You

[email protected]@ee.doe.gov

[email protected]

[email protected]

hydrogenandfuelcells.energy.gov

Fcto Webinarslides Highly Efficient Solar Tc Reaction Systems 011315

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