HYDROSOL-3D (FCH JU-2425224)

Souzana Lorentzou Aerosol & Particle Technology Laboratory/

CPERI / CERTH (Coordinator)

HYDROSOL 3D & Partnership description

HYDROSOL 3D

Scale Up of Thermochemical HYDROgen Production in a SOLar Monolithic Reactor: a 3rd Generation Design Study

Duration: 01/01/10-31/12/12

Design of a 1MW Pilot Plant

FCH JU Budget: 1.73M€, EU Funding: 0.98M€

• Aerosol & Particle Technology Laboratory (Coordinator)

• DLR, Deutsches Zentrum für Luft und Raumfahrt

• CIEMAT, Centro de Investigaciones Energéticas, MedioAmbientales Y Tecnológicas

• TOTAL S.A.

• HYGEAR

0

0.001

0.002

0.003

0.004

0.005

0.006

160 210 260 310 360 410 460

Time (min)

H2 &

O2 (

mm

ole

s*gr

ed

ox-1

*min

-1)

0

200

400

600

800

1000

1200

1400

Tem

pe

rature

(C)

H2 mmoles/ gsolid/min

O2 mmoles/ gsolid/min

T (C)

0.0000

0.0025

0.0050

0.0000

0.0025

0.0050

0.0000

0.0025

0.0050

150 200 250 300 350 400 450

0.0000

0.0025

0.0050

NiFe2O

4, SHS

H2,

O2 c

on

cen

trati

on

(m

mo

les*m

in-1*g

-1

red

ox m

ate

rial)

H2

O2

tTR

=30 min

tWS

=30 min

0

500

1000

1500

TWS

=1100oC

TWS

=1000oC

TWS

=800oC

TWS

=700oC

0

500

1000

1500

Grinding

Tem

pera

ture

(oC

)

0

500

1000

1500

Time (min)

0

500

1000

1500

T

HYDROSOL-3D achievements

• Fine-tuning of metal oxide redox materials

• Shaping into an absorber/monolithic structure

porous ceramic body

coated monolith redox material shaped bodies

Redox Material In-house designed hydraulic press

Redox material shaped bodies

Redox Material In-house designed hydraulic press

Redox material shaped bodies

in-house designed

hydraulic press

redox material

redox material shaped bodies

powder

HYDROSOL-3D achievements

• Steady state simulation of the process

• Exergy analysis

Process unit Ef [kW]

EP [kW]

ED [kW]

εk [%] yk[%]

Solar reactor 896 283 613 31.59 60.51

Pre-heater 3.26 1.26 2 38.65 0.19

Evaporator 1 35.89 14.02 21.87 39.06 2.15

Evaporator 2 41.03 20.59 20.44 50.18 2.01

Super-heater 4.69 3.97 0.7 84.64 0.1x10-3

PSA 16.05 3.84 12 23.92 1.18

H2 compression 16.04 7.06 8.98 44.01 0.88

Overall system 1013 334 679 32.95

• High exergy destruction ratio → Optimization of solar reactor & evaporators

Reaction

Solair-

cups

Regneration

Solar reactor

H2O Tank

H2

storage

Pre-heater

Pump

Air

condenser

Compression

of Hydrogen

Evaporator 1

Evaporator 2

Super-

heater

O2/N2

N2

H2/N2/H2O(g)

Cooling water

Cooling water

Cooling water

Cooling water

N2

N2 Tank

H2O(l)

H2

H2O(l)

H2O(l)

PSA

PSA

N2/H2

H2

H2O(g)

Cooling water

Cooling water

S18

S30

S31

S1S2S3S4

S5

S7

S16

S8

S6

S9

S20

S21

S10

S31

S11

S12

S14

S15

S22

HYDROSOL-3D achievements

Integration of the HYDROSOL plant into a solar tower

Buffer level

Outlet level

Reactor Chamber

Absorber Possible shapes Max. Quality value [-] Flat 0,26

Conical 0,72 Spherical 0,94

• Design of secondary concentrator

• New Receiver/Reactor Design

Spherical shape

HYDROSOL-3D achievements

• Control concept based on HYDROSOL-II experience

• Development of a control/system program

• Steady state simulation of the process

StateMachine

Solar fieldmodel

Reactormodel

Temperaturecontrol

StateMachine

Solar fieldmodel

Reactormodel

Temperaturecontrol

• Pilot plant operation for validation of process strategies and optimization of critical process parameters

Experimental test in Hydrosol facility with the automatic control

Supervisory control and data acquisition interface

Heliostat field distribution

• Development, construction and operation of a lab-scale H2 drying unit (PSA-based)

HYDROSOL-3D achievements

• Refinement & evaluation of rate equations • Simulation of reactor performance

0.0

2.0

4.0

6.0

8.0

10.0

12.0

0.0E+00 1.0E+04 2.0E+04 3.0E+04 4.0E+04 5.0E+04 6.0E+04

Time (s)

H2 a

nd

O2 (

μm

ole

s/g r

ed

ox/

s)

H2 experiment

O2 experiment

model

H2

O2

Anticipated advances (beyond the SoA) after the completion of the project include:

• Redox reactor with long-term cyclic operation stability (a total of over 70 cycles)

under operation at high temperature solar irradiation (up to 1200oC)

• Ability to construct monolithic porous structures consisting entirely of the redox material

• Ability to construct a redox reactor with increased thermal uniformity

• A software tool for process engineering simulation at the MW scale

• Complete layouts of the whole plants and design of all specific components

HYDROSOL-3D achievements Technical Accomplishments & Progress

towards overall project and SoA

Alignment to MAIP/AIP

AIP 2008 objective: Development of new reactor concepts with enhanced efficiency and scalability for future application

• Design of a new solar receiver/reactor for the production of H2O via H2O-splitting.

Improved, more efficient, scaled up version (1 MW) of the established HYDROSOL reactor concept.

Optimized Hydrogen production

Enhanced transport, thermal and heat recovery properties

AIP 2008 objective: Simulation of the reactor-system

• The control procedure of the pilot plant was simulated. The operational ranges and the process parameters were optimized, while process strategies were validated through pilot plant operation

• Modeling/simulation of core components and of the process as a whole

AIP 2008 objective: Design and simulation of a scaled-up system for a demonstration in the MW range

• Design of an integrated solar system of 1 MW scale

• A new improved solar reactor

A reactor dedicated to solar thermochemical water splitting, customized to the

solar tower plant design

Extensive modeling & simulation activities

A secondary concentrator for the reduction of radiation losses

A design that minimizes heat losses and enhances heat recovery

Alignment to MAIP/AIP

Topic: SP1-JTI-FCH.2.3: Water decomposition with solar heat Sources (Call: 2008)

AIP expected outcome Project Objectives Status M Development of new high temperature reactors, component improvements

Design of a reactor integrated with a solar tower 12

Simulation of the components and systems

Simulation of the Pilot Plant 24

Simulation of core components and of the process as a whole 33

Design study of a scaled up reactor

Design of 1 MW reactor for high-temperature H2O-splitting, according to the following targets: 33

Integrated process concept 33

Automation and control concept 33

Techno-economic study to determine the feasibility of the scale up of the process to industrial application.

36

Comparison with the expected outcome AIP

Within the 3 years of the project, the HYDROSOL consortium

• Has presented HYDROSOL-3D results so far in

• 6 scientific journals

• 12 Scientific conferences

• 3 exhibitions & fairs

• Has supervised 4 Diploma thesis , 1 Master thesis

• Has supervised 1 PhD thesis

Dissemination Activities

Technology Transfer / Collaborations

which:

Technology transfer from the HYDROSOL-3D :

• Partners of the consortium have proceeded with the submission of the HYDROSOL-PLANT proposal which is the natural evolutionary step after HYDROSOL-3D, has received a high grade during the FCH-JU evaluation procedure and is in the pending list

• Partners of the consortium are participating in the RESTRUCTURE project which is based on the concept of honeycomb reactors for thermochemical processes

• National projects and regional collaborations have occurred

European Commission and FCH-JU

for supporting our project

Acknowledgments

Thank you for your attention!

More Info at: http://www.hydrosol3d.org/ & http://www.hydrosol-project.org/