Economical analysis of ethanol steam reformer for hydrogen production associated with a sugarcane industry

An expressive amount of produced hydrogen is generated by customers in-situ such as petrochemical, fertilizer and sugarcane industries. However, the most utilized feedstock is natural gas, a non-renewable and fossil fuel. The introduction of biohydrogen production process associated in a sugarcane industry is an alternative to diminish emissions and contribute to create a CO2 cycle, where the plants capture this gas by photosynthesis process and produces sucrose for ethanol production. The cost of production of ethanol has dramatically decreased (from about US$ 700/m3 in 1970s to US$ 200/m3 today), becoming this a good option at near term, inclusively for its utilization by customers localized in main regions (localized especially in regions such as Southeastern Brazil) Also in near future, it will possible the utilization of fuel cells as form of distributed generation. Its utilization could occur specially in peak hours, diminishing the cost of investments in newer transmission systems. A technical and economic analysis of steam reformer of ethanol to hydrogen production associated with sugarcane industry was recently performed. This technique will also allow the use of ethanol when its price is relatively low. This study was based on a previous R&D study (sponsored by CEMIG - State of Minas Gerais Electricity Company) where thermodynamic and economic analyses were developed, based in the development of two ethanol steam reformers prototypes.x In this study an analysis was performed considering the use of bagasse as source of heat in the steam reforming process. Its use could to diminish the costs of hydrogen production, especially at large scale, obtaining cost-competitive production and permitting that sugarcane industry produces hydrogen in large scale beyond ethylic alcohol, anhydrous alcohol (or ethanol) and sugar.

Hydrogen production by biogas steam reforming: A technical, economic and ecological analysis

Fuel cells are electrochemical energy conversion devices that convert fuel and oxidant electrochemically into electrical energy, water and heat. Compared to traditional electricity generation technologies that use combustion processes to convert fuel into heat, and then into mechanical energy, fuel cells convert the hydrogen and oxygen chemical energy into electrical energy, without intermediate conversion processes, and with higher efficiency. In order to make the fuel cells an achievable and useful technology, it is firstly necessary to develop an economic and efficient way for hydrogen production. Molecular hydrogen is always found combined with other chemical compounds in nature, so it must be isolated. In this paper, the technical, economical and ecological aspects of hydrogen production by biogas steam reforming are presented. The economic feasibility calculation was performed to evaluate how interesting the process is by analyzing the investment, operation and maintenance costs of the biogas steam reformer and the hydrogen production cost achieved the value of 0.27 US$/kWh with a payback period of 8 years. An ecological efficiency of 94.95%, which is a good ecological value, was obtained. The results obtained by these analyses showed that this type of hydrogen production is an environmentally attractive route. © 2013 Elsevier Ltd.

Physical-chemical and thermodynamic analyses of ethanol steam reforming for hydrogen production

Steam reforming is the most usual method of hydrogen production due to its high production efficiency and technological maturity the use of ethanol for this purpose is an interesting option because it is a renewable and environmentally friendly fuel. The objective of this article is to present the physical-chemical, thermodynamic, and exergetic analysis of a steam reformer of ethanol, in order to produce 0.7 Nm(3)/h of hydrogen as feedstock of a 1 kW PEMFC the global reaction of ethanol is considered. Superheated ethanol reacts with steam at high temperatures producing hydrogen and carbon dioxide, depending strongly on the thermodynamic conditions of reforming, as well as on the technical features of the reformer system and catalysts. The thermodynamic analysis shows the feasibility of this reaction in temperatures about 206 degrees C. Below this temperature, the reaction trends to the reactants. The advance degree increases with temperature and decreases with pressure. Optimal temperatures range between 600 and 700 degrees C. However, when the temperature attains 700 degrees C, the reaction stability occurs, that is, the hydrogen production attains the limit. For temperatures above 700 degrees C, the heat use is very high, involving high costs of production due to the higher volume of fuel or electricity used. The optimal pressure is 1 atm., e.g., at atmospheric pressure. The exergetic analysis shows that the lower irreversibility is attained for lower pressures. However the temperature changes do not affect significantly the irreversibilities. This analysis shows that the best thermodynamic conditions for steam reforming of ethanol are the same conditions suggested in the physical-chemical analysis.

Analysis of the performance of an extraction-condensation steam turbine on a cogeneration system of a Brazilian sugar-alcohol factory

In this work a detailed thermodynamic analysis for an extraction-condensation steam turbine capable to drive a 40 MVA electricity generator in a sugar-alcohol factory was carried out. The use of this turbine in the cogeneration system showed that its efficiency contributed to increase the power generation, although the condensation reduces the overall efficiency of the plant. Sensibility analyses were performed to evaluate the behavior of the overall energy efficiency of a plant with the extraction-condensation turbine in function of the boiler efficiency, the specific consumption of steam in the processes and the condensation rate in the turbine. It was observed that the plant efficiency is very sensible to the condensation rate variation and it increases when there is an increase in the demand of steam for processes.

Physical-chemical and thermodynamic analyses of steam reforming of ethanol to hydrogen production

The steam reforming is one of most utilized process of hydrogen production because of its high production efficiencies and its technological maturity. The use of ethanol for this purpose is a interesting option because this is a renewable and less environmentally offensive fuel. The objective of this study is evaluate the physical-chemical, thermodynamic and environmental analyses of steam reforming of ethanol. whose objective is to produce 0.7 Nm3/h of hydrogen to be used by a PEMFC of l kW. In this physical-chemical analysis, a global reaction of ethanol was considered. That is, the superheated ethanol and steam, at high temperatures, react to produce hydrogen and carbon dioxide. Beyond it's the simplest form to study the steam reforming of ethanol to hydrogen production, it's the case where occurs the highest production of hydrogen (the product to be used by fuel cells) and carbon dioxide, to be eliminated. But this reaction isn't real and depends greatly on the thermodynamic conditions of reforming, technical features of reformer system and catalysts. Other products generally formed (but not investigated in this study) are methane, carbon monoxide, among others. It was observed that the products is commonly produced in the moment when the reaction attains temperatures about 206°C (below this temperature, the reaction trend to the reaetants, that is, from hydrogen and carbon dioxide to steam and ethanol) and the advance degree of this reaction increases when the temperature of reaction also increases and when its pressure decreases. It's suggested reactions at about 600°C or higher. However, when the temperature attains 700°C, the stability of this reaction is occurred, that is, the production of reaction productions attains to the limit, that is the highest possible production. In temperatures above 700°C, the use of energy is very high for produce more products, having higher costs of production that the suggested temperature. The indicated pressure is 1 atm., a value that allows a desirable economy of energy that would also be used for pressurization or depressurization of steam reformer. In exergetic analysis, it's seem that the lower irreversibililies occur when the pressure of reactions are lower. However, the temperature changes don't affect significantly the irreversibilites. Utilizing the obtained results from this analysis, it was concluded that the best thermodynamic conditions for steam reforming of ethanol is the same conditions suggested in the physical-chemical analysis. The exergetic and first law efficiencies are high on the thermodynamie conditions studied.

Thermal Characteristics of Lignin Residue from Industrial Processes

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Computationsl modelling of dimethyl ether separation and steam reforming in fluidized bed reactors

This study presents a computational fluid dynamic (CFD) study of Dimethyl Ether (DME) gas adsorptive separation and steam reforming (DME-SR) in a large scale Circulating Fluidized Bed (CFB) reactor. The CFD model is based on Eulerian-Eulerian dispersed flow and solved using commercial software (ANSYS FLUENT). Hydrogen is currently receiving increasing interest as an alternative source of clean energy and has high potential applications, including the transportation sector and power generation. Computational fluid dynamic (CFD) modelling has attracted considerable recognition in the engineering sector consequently leading to using it as a tool for process design and optimisation in many industrial processes. In most cases, these processes are difficult or expensive to conduct in lab scale experiments. The CFD provides a cost effective methodology to gain detailed information up to the microscopic level. The main objectives in this project are to: (i) develop a predictive model using ANSYS FLUENT (CFD) commercial code to simulate the flow hydrodynamics, mass transfer, reactions and heat transfer in a large scale dual fluidized bed system for combined gas separation and steam reforming processes (ii) implement a suitable adsorption models in the CFD code, through a user defined function, to predict selective separation of a gas from a mixture (iii) develop a model for dimethyl ether steam reforming (DME-SR) to predict hydrogen production (iv) carry out detailed parametric analysis in order to establish ideal operating conditions for future industrial application. The project has originated from a real industrial case problem in collaboration with the industrial partner Dow Corning (UK) and jointly funded by the Engineering and Physical Research Council (UK) and Dow Corning. The research examined gas separation by adsorption in a bubbling bed, as part of a dual fluidized bed system. The adsorption process was simulated based on the kinetics derived from the experimental data produced as part of a separate PhD project completed under the same fund. The kinetic model was incorporated in FLUENT CFD tool as a pseudo-first order rate equation; some of the parameters for the pseudo-first order kinetics were obtained using MATLAB. The modelling of the DME adsorption in the designed bubbling bed was performed for the first time in this project and highlights the novelty in the investigations. The simulation results were analysed to provide understanding of the flow hydrodynamic, reactor design and optimum operating condition for efficient separation. Bubbling bed validation by estimation of bed expansion and the solid and gas distribution from simulation agreed well with trends seen in the literatures. Parametric analysis on the adsorption process demonstrated that increasing fluidizing velocity reduced adsorption of DME. This is as a result of reduction in the gas residence time which appears to have much effect compared to the solid residence time. The removal efficiency of DME from the bed was found to be more than 88%. Simulation of the DME-SR in FLUENT CFD was conducted using selected kinetics from literature and implemented in the model using an in-house developed user defined function. The validation of the kinetics was achieved by simulating a case to replicate an experimental study of a laboratory scale bubbling bed by Vicente et al [1]. Good agreement was achieved for the validation of the models, which was then applied in the DME-SR in the large scale riser section of the dual fluidized bed system. This is the first study to use the selected DME-SR kinetics in a circulating fluidized bed (CFB) system and for the geometry size proposed for the project. As a result, the simulation produced the first detailed data on the spatial variation and final gas product in such an industrial scale fluidized bed system. The simulation results provided insight in the flow hydrodynamic, reactor design and optimum operating condition. The solid and gas distribution in the CFB was observed to show good agreement with literatures. The parametric analysis showed that the increase in temperature and steam to DME molar ratio increased the production of hydrogen due to the increased DME conversions, whereas the increase in the space velocity has been found to have an adverse effect. Increasing temperature between 200 oC to 350 oC increased DME conversion from 47% to 99% while hydrogen yield increased substantially from 11% to 100%. The CO2 selectivity decreased from 100% to 91% due to the water gas shift reaction favouring CO at higher temperatures. The higher conversions observed as the temperature increased was reflected on the quantity of unreacted DME and methanol concentrations in the product gas, where both decreased to very low values of 0.27 mol% and 0.46 mol% respectively at 350 °C. Increasing the steam to DME molar ratio from 4 to 7.68 increased the DME conversion from 69% to 87%, while the hydrogen yield increased from 40% to 59%. The CO2 selectivity decreased from 100% to 97%. The decrease in the space velocity from 37104 ml/g/h to 15394 ml/g/h increased the DME conversion from 87% to 100% while increasing the hydrogen yield from 59% to 87%. The parametric analysis suggests an operating condition for maximum hydrogen yield is in the region of 300 oC temperatures and Steam/DME molar ratio of 5. The analysis of the industrial sponsor’s case for the given flow and composition of the gas to be treated suggests that 88% of DME can be adsorbed from the bubbling and consequently producing 224.4t/y of hydrogen in the riser section of the dual fluidized bed system. The process also produces 1458.4t/y of CO2 and 127.9t/y of CO as part of the product gas. The developed models and parametric analysis carried out in this study provided essential guideline for future design of DME-SR at industrial level and in particular this work has been of tremendous importance for the industrial collaborator in order to draw conclusions and plan for future potential implementation of the process at an industrial scale.

Modelització i control d'un reactor de producció d'hidrogen per a l'alimentació de piles de combustible

Les piles de combustible permeten la transformació eficient de l’energia química de certs combustibles a energia elèctrica a través d’un procés electroquímic. De les diferents tecnologies de piles de combustible, les piles de combustible de tipus PEM són les més competitives i tenen una gran varietat d’aplicacions. No obstant, han de ser alimentades únicament per hidrogen. Per altra banda, l’etanol, un combustible interessant en el marc dels combustibles renovables, és una possible font d’hidrogen. Aquest treball estudia la reformació d’etanol per a l’obtenció d’hidrogen per a alimentar piles de combustible PEM. Només existeixen algunes publicacions que tractin l’obtenció d’hidrogen a partir d’etanol, i aquestes no inclouen l’estudi dinàmic del sistema. Els objectius del treball són el modelat i l’estudi dinàmic de reformadors d’etanol de baixa temperatura. Concretament, proposa un model dinàmic d’un reformador catalític d’etanol amb vapor basat en un catalitzador de cobalt. Aquesta reformació permet obtenir valors alts d’eficiència i valors òptims de monòxid de carboni que evitaran l’enverinament d’una la pila de combustible de tipus PEM. El model, no lineal, es basa en la cinètica obtinguda de diferents assaigs de laboratori. El reformador modelat opera en tres etapes: deshidrogenació d’etanol a acetaldehid i hidrogen, reformat amb vapor d’acetaldehid, i la reacció WGS (Water Gas Shift). El treball també estudia la sensibilitat i controlabilitat del sistema, caracteritzant així el sistema que caldrà controlar. L’anàlisi de controlabilitat es realitza sobre la resposta de dinàmica ràpida obtinguda del balanç de massa del reformador. El model no lineal és linealitzat amb la finalitat d’aplicar eines d’anàlisi com RGA, CN i MRI. El treball ofereix la informació necessària per a avaluar la possible implementació en un laboratori de piles de combustibles PEM alimentades per hidrogen provinent d’un reformador d’etanol.

Análise do aproveitamento do gás natural em plantas de cogeração e trigeração de energia em indústrias frigoríficas

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Análise técnica e econômica de um reformador de etanol para produção de hidrogênio

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Análise técnica, econômica e ecológica do uso de biogás em célula a combustível de óxido sólido (SOFC)

Pós-graduação em Engenharia Mecânica - FEG

Supercritical steam cycles and biomass integrated gasification combined cycles for sugarcane mills

Back in 1970s and 1980s, cogeneration plants in sugarcane mills were primarily designed to consume all bagasse, and produce steam and electricity to the process. The plants used medium pressure steam boilers (21 bar and 300 degrees C) and backpressure steam turbines. Some plants needed also an additional fuel, as the boilers were very inefficient. In those times, sugarcane bagasse did not have an economic value, and it was considered a problem by most mills. During the 1990s and the beginning of the 2000s, sugarcane industry faced an open market perspective, thus, there was a great necessity to reduce costs in the production processes. In addition, the economic value of by-products (bagasse, molasses, etc.) increased, and there was a possibility of selling electricity to the grid. This new scenario led to a search for more advanced cogeneration systems, based mainly on higher steam parameters (40-80 bar and 400-500 degrees C). In the future, some authors suggest that biomass integrated gasification combined cycles are the best alternative to cogeneration plants in sugarcane mills. These systems might attain 35-40% efficiency for the power conversion. However, supercritical steam cycles might also attain these efficiency values, what makes them an alternative to gasification-based systems. This paper presents a comparative thermoeconomic study of these systems for sugarcane mills. The configurations studied are based on real systems that could be adapted to biomass use. Different steam consumptions in the process are considered, in order to better integrate these configurations in the mill. (C) 2009 Elsevier Ltd. All rights reserved.

Optimization of hydrogen plant efficiency

The purpose of this master’s thesis was to study ways to increase the operating cost-efficiency of the hydrogen production process by optimizing the process parameters while, at the same time, maintaining plant reliability and safety. The literature part reviewed other hydrogen production and purification processes as well as raw material alternatives for hydrogen production. The experimental part of the master’s thesis was conducted at Solvay Chemicals Finland Oy’s hydrogen plant in spring 2012. It was performed by changing the process parameters, first, one by one, aiming for a more efficient process with clean product gas and lower natural gas consumption. The values of the process parameters were tested based on the information from the literature, process simulation and experiences of previous similar processes. The studied parameters were reformer outlet temperature, shift converter inlet temperature and steam/carbon ratio. The results show that the optimal process conditions are a lower steam/carbon ratio and reformer outlet temperature than the current values of 3.0 and 798 °C. An increase/decrease in the shift conversion inlet temperature does not affect natural gas consumption, but it has an effect on minimizing the process steam overload.