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The ORBIT-Project: Biological methanation in a trickle-bed reactor - key results and next steps
(2021)
Simulation and Techno-Economic Analysis of a Power-to-Hydrogen Process for Oxyfuel Glass Melting
(2021)
As an energy-intensive industry sector, the glass industry is strongly affected by the increasingly stringent climate protection targets. As established combustion-based production systems ensure high process stability and glass quality, an immediate switch to low greenhouse gas emission processes is difficult. To approach these challenges, this work investigates a step-by-step integration of a Power-to-Hydrogen concept into established oxyfuel glass melting processes using a simulation approach. This is complemented by a case study for economic analysis on a selected German glass industry site by simulating the power production of a nearby renewable energy park and subsequent optimization of the power-to-hydrogen plant performance and capacities. The results of this study indicate, that the proposed system can reduce specific carbon dioxide emissions by up to 60%, while increasing specific energy demand by a maximum of 25%. Investigations of the impact of altered combustion and furnace properties like adiabatic flame temperature (+25 °C), temperature efficiency (∆ξ = −0.003) and heat capacity flow ratio (∆zHL = −0.009) indicate that pure hydrogen-oxygen combustion has less impact on melting properties than assumed so far. Within the case study, high CO2 abatement costs of 295 €/t CO2-eq. were determined. This is mainly due to the insufficient performance of renewable energy sources. The correlations between process scaling and economic parameters presented in this study show promising potential for further economic optimization of the proposed energy system in the future.
Green hydrogen via renewable powered electrolysis has a high relevance in decarbonization and supply security. Achieving economically competitive hydrogen production costs is a major challenge in times of an energy price crisis. Our objective is to show the economically optimal installed capacity of electrolysers in relation to wind and solar power so swift and credible statements can be made regarding the system design. The ratio between renewable generation and electrolysis power as well as scaling effects, operating behaviour and development of costs are considered. Hydrogen production costs are calculated for four exemplary real PV and wind sites and different ratios of electrolysis to renewable power for the year 2020. The ideal ratio for PV systems is between 14% and 73% and for wind between 3.3% and 143% for low and high full load hours. The lowest hydrogen production costs are identified at 2.53 €/kg for 50 MW wind power and 72 MW electrolysis power. The results provide plant constructors the possibility to create a cost-optimized design via an optimum ratio of electrolysis to renewable capacity. Therefore, the procedures for planning and dimensioning of selected systems can be drastically simplified.
In this study, a pilot-scale trickle-bed reactor for biological methanation and various scale-up scenarios for 2023 and 2050 were investigated using LCA. A best- and worst-case scenario for technology development until 2050 was evolved using cross consistency analysis and morphological field, based on which the data for the ecological models were determined.The results show that the plant scale-up has a very positive effect on the ecological consequences of methanation. In the best-case scenario, the values are a factor of 23-780 lower than those of the actual plant today. A hot-spot analysis showed that especially electrolysis operation has a large impact on total emissions. The final Monte-Carlo simulation shows that the technology is likely to achieve a low GWP with a median of 104.0 kg CO2-eq / MWh CH4.
Based on a prospective scenario analysis, possible vehicle fleet developments for the individual motor car traffic (vehicle categories N1 and M1) are investigated for Germany in order to determine the long-term vehicle fleet structure, final energy demand, and related carbon dioxide emissions until the year 2050. In this framework, a vehicle fleet model was developed which combines a bottom-up consumer demand model with a dynamic stock-flow approach. Special emphasis is thereby given to different electric power-trains and synthetic gaseous fuels based on the power-to-gas technology. In detail, two different main scenarios are developed and, in addition, the impact of different carbon dioxide taxation levels of fossil fuels on the vehicle fleet structure are analysed. The scenario results reveal a broad range of possible future vehicle fleet structures. In the short to medium timeframe, the internal combustion engine dominates the fleet as a result of efficiency improvements and an increased use of natural gas as automotive fuel. The development of electric power-trains is initially marked by hybrid vehicles, whereas battery electric vehicles dominate the fleet structure in the long-term. Under favourable conditions, also synthetic gaseous fuels are competitive which can reduce carbon dioxide emissions even further.
There are several approaches to classifying energy storage systems (see Chaps. 1 and 2). Storage systems are used in a large number of different technologies at various stages of development, and in a wide range of application areas (see Chaps. 3 to 5). This chapter compares the capabilities of the different storage systems using the following criteria:This comparison of storage systems also provides a convenient overview of the various storage systems and their capabilities.
Coupling energy sectors within the emerging residential PV prosumer systems is necessary for an optimised use of the houseowners’ own produced electricity. But the pure availability of different energy technologies in the system is not enough. By optimising the electricity usage as well as the capacities of PV generators, storage technologies, heat pumps and battery electric vehicles, not only the best solution in a technical point of view can be achieved, the need of finding the most financially beneficial system composition for single-family houses and tenements is possible. The study provides a detailed model for average German single-family houses and tenements and results for the energy transition period until 2050 for the optimised energy systems regarding optimised PV and stationary battery capacities and different heat storage capacities. Most noticeable outcomes can be observed by using a vehicle-to-home car, where a car can mostly take over the tasks of a stationary battery and by introducing a solidarity model using this type of car in tenement systems.
Due to the very high fossil energy demand, the glass industry is looking for innovative approaches for the reduction of CO2 emissions and the integration of renewable energy sources. In this paper, we present a novel power-to-gas concept, which has no impact on established melting processes and discuss it for this purpose. A special focus is set on the required CO2 capture from typical flue gases in the glass industry, as this process has not been investigated in detail yet. We used a process simulation approach to investigate post-combustion CO2 capture by absorption processes, followed by a techno-economic evaluation. Our investigations found the designed CO2 capture plant to be approx. 400 times smaller than absorption based CO2 separation processes for conventional power plants. Due to the many options for waste heat utilization, the waste heat required for CO2 desorption can be generated in a particularly efficient and cost-effective way. The resulting CO2 avoidance costs range between 41-42 €/t CO2, depending on waste heat utilization for desorption, and thus offer a cost effective way of CO2 removal from glass industry melting processes. These costs are well below the values of 50-65 €/t CO2 described so far for comparable industrial applications. In addition, we describe optimization options, like solvent and process improvements, to enable further cost reductions. These results motivate further research and development on the overall process presented in this work.
The hydrogen gas-to-liquid mass transfer is the limiting factor in biological methanation. In trickle-bed reactors, mass transfer can be increased by high flow velocities in the liquid phase, by adding a packing material with high liquid hold-up or by using methanogenic archaea with a high methane productivity. This study developed a polyphasic approach to address all methods at once. Various methanogenic strains and packings were investigated from a microbial and hydrodynamic perspective. Analyzing the ability to produce high-quality methane and to form biofilms, pure cultures of Methanothermobacter performed better than those of the genus Methanothermococcus. Liquid and static hold-up of a packing material and its capability to facilitate attachment was not attributable to a single property. Consequently, it is recommended to carefully match organism and packing for optimized performance of trickle-bed reactors. The ideal combination for the ORBIT system was identified as Methanothermobacter thermoautotrophicus IM5 and DuraTop (R).