One Step Biomass Gas Reforming-Shift Separation Membrane ... · ─4.1 Design of membrane module...
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One Step Biomass Gas Reforming-Shift Separation Membrane Reactor
2010 DOE Hydrogen Program Review June 7, 2010
Michael Roberts Co-PI GTIRazima Souleimanova Co-PI-presenter GTIBryan Morreale National Energy Technology LaboratoryMark Davis Schott North AmericaBrett Krueger Wah Chang (an Allegheny Company)
Project ID PD070
This presentation does not contain any proprietary, confidential, or otherwise restricted information.
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Overview
Timeline> Start: 02/01/2007> End: 06/30/2013> Percent complete: 35%
Budget> Total project funding: $3,396,186
─DOE share: $2,716,949─Contractors share: $679,237
> Funding received in FY09: $0> Funding for FY10: $350,000
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Overview (con’t)
Barriers>Hydrogen Production from Biomass Barriers
G. Efficiency of Gasification, Pyrolysis, and Reforming Technology I. Impurities N. Hydrogen Selectivity O. Operating Temperature P. Flux
>DOE Technical Targets─ $2-3/kg H2 from biomass delivered target─ $1.60/kg H2 from biomass without delivery
Partners>Arizona State University>National Energy Technology Laboratory>Schott North America>Wah Chang, an Allegheny Technology Company
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Relevance: Technical Targets: Dense Metallic Membranes for Hydrogen Separation and Purificationa
Performance Criteria Units 2006 Status 2010 Target 2015 Target
Flux Rateb scfh/ft2 >200 250 300
Module Cost (+ membrane material)c $/ft2 of membrane 1,500 1,000 <500
Durabilityd hr <8,760 26,280 >43,800
Operating Capabilitye psi 200 400 400-600
Hydrogen Recovery % 60 >80 >90
Hydrogen Qualityf % of total (dry) gas
99.98 99.99 >99.99
A Based on membrane water-gas shift reactor with syngas. B Flux at 20 psi hydrogen partial pressure differential with a minimum permeate side total pressure of 15 psig, preferably >50 psi and 400°C. C Although the cost of Pd does not present a significant cost barrier due to the small amount used, the equipment and labor associated with
depositing the material (Pd), welding the Pd support, rolling foils or drawing tubes account for the majority of membrane module costs. The $1,500 cost status is based on emerging membrane manufacturing techniques achieved by our partners and is approximately $500below commercially available units used in the microelectronics industry.
D Intervals between membrane replacements. E Delta P operating capability is application dependent. There are many applications that may only require 400 psi or less. For coal
gasification 1000 psi is the target. F It is understood that the resultant hydrogen quality must meet the rigorous hydrogen quality requirements as described in Appendix C.
These membranes are under development to achieve that quality. Membranes must also be tolerant to impurities. This will be application specific. Common impurities include sulfur and carbon monoxide.
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Relevance: Project Objectives
Long-term goal:
Determine the technical and economic feasibility of using the gasification membrane reactor to produce hydrogen from biomass
Short-term goal:
Evaluation of synthesized metallic and glass ceramic membranes to fabricate a module for testing with the bench scale gasifier
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Approach: Scope of Work
> Task 1. Membrane material development─ 1.1 Ceramic material synthesis & testing─ 1.2 Metallic material synthesis & testing─ 1.3 Composite membrane synthesis & testing─ 1.6 Optimization of selected candidate membranes
> Task 2. Gasification membrane reactor process development and economic analysis
> Task 3. Bench-scale biomass gasifier design and construction
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Approach: Scope of Work (Continued)
> Task 4. Integrated testing of initial membrane with gasifier─ 4.1 Design of membrane module configuration─ 4.2 Membrane module fabrication─ 4.3 Testing of bench-scale membrane reactor
> Task 5. Integrated testing of best candidate membrane with gasifier
> Task 6. Project Management and Reporting
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Approach Milestones
Task Revised/Planned
1.4 Select Initial Candidate Membrane 6/30/08
1.5 Select Best Candidate Membrane 12/30/11
2.0 Process Development & Econ Analysis 9/30/10
6/30/12
4.1 Membrane Module Design 6/30/10
2.0 Integrated Testing with bench gasifier 6/30/12
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Approach: Conventional Hydrogen Production from Biomass Gasification and Biomass Gasifier with Close Coupled Membrane
Gasifier
biomass
oxygensteam CO2
H2
oxygensteam CO2
Power generation
removalCO2
cleaningGas
Membrane
GasifierC
yclo
ne
biomass
oxygensteamoxygensteam
Powergeneration
CO2removal
Gascleaning
Cyc
lone Shift
reactionGasifier PSA H2
CO2
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Approach: GTI’s Fluidized Bed Gasifier RENUGAS®
Ideal for Membrane Gasification Reactor
Raw Product GasBiomass Feed
Feed Lockhopper
G asificationzone
2nd-STAGECYCLONE
1st-STAGECYCLONE
STEAM/OXYGENOR AIR
ASHLOCKHOPPER
ASH
Membrane module Disengaging zone
T:700~900°C
P:20~60 atm
H2, CO, CO2, H2O each 15~25%
CH4: 5~10%
Contaminants
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Approach: Potential Benefits of Membrane Reactor for Hydrogen Production from Biomass
High H2 production efficiency: Thermodynamic analysis indicates potentially over 40%
improvement in H2 production efficiency over the current gasification technologies
Low cost: reduce/eliminate downstream processing steps
Clean product:no further conditioning needed, pure hydrogen
CO2 sequestration ready: simplify CO2 capture process
Power co-generation: utilization of non-permeable syngas
Eliminate loss in PSA tail gas
More CO shift H2O+CO = CO2+H2
Reform CH4 CH4+H2O = CO+3H2
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“ODS” (oxide dispersion stabilized) alloy
BH9-147 = Pd7Pt2Al annealed 800 C in air 1 hour to “force” oxide growth
Al,OPd,Pt,Al
Pd,Pt
BackscatteredSecondary
PdPtAl
Technical Accomplishments and Progress: Metallic Membranes-DOE NETL
Addition of Stabilizing Elements
Select elements have shown promise in enhancing corrosionresistance, mechanical strength and stabilization of grainboundaries.
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Technical Accomplishments and Progress: Membrane Performance in H2 - DOE-NETL
1.0E-09
1.0E-08
1.0E-07
0.85 0.90 0.95 1.00 1.05 1.10
1000/Temperature [1/K]
H2 P
erm
eabi
lity
[mol
/ m
/ s /
Pa0.
5 ]
Koffler Pd Reference69Pd-Pt95Pd-Au94Pd-Co77Pd-Ag94Pd-Ni80Pd-Cu70Pd-Cu65Pd-Cu
850oC 650oC700oC750oC800oC900oC
Pd4Pt
Pd7Pt2Al
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Technical Accomplishments and Progress: Metal-Glass-Ceramic Membranes- Schott
Segregation of appropriate metals (e.g., Ag-Pd) along grain boundaries during high degrees of crystallization for selected compositions
Combined ion-exchange (e.g., Ag-Pd) and heat treatment under a reducing atmosphere
Co-sintering of glassy powder + metal (e.g., Ag-Pd) to produce a high metal content-containing glass-ceramic
Membrane Ceramizationconditions: temperature, atmosphere
Hydrogen permeation,SCFH/FT2
Temperature, °C
Pressure difference, psi
Electronicconductivity, S/cm at 600°C
CMAS-1/3 Glass-no Pd
unceramized 0 850 11.8 4 x 10-8
CMAS-1/2 w/Pd Glass
unceramized 0.02 850 7.4 4 x 10-9
CMAS-1/2D w/Pd
1100°C, H2/N2 0.15 350 35.7 7 x 10-7
CMAS-1/2D w/Pd
1100°C, H2/N2 0.25 850 12.0 7 x 10-7
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Technical Accomplishments and Progress: Metallic Membranes- GTI
Surface oxide layer: chemical etching, electrochemistry
Catalytic protective layer: electrochemistry
Hydrogen embrittlement: use alloy instead of pure metals
Permeability at T=850 CPdCu, PdAg, PdAuPdNi, NiCuCo, NiFeCoMo, VNiPdTi, Ta, V
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Technical Accomplishments and Progress: Selection of Initial Candidate Membrane
Pd-Cu foil was identified as an initial membrane candidate and screened using the following sequence of experiments:
• H2/He permeation testing at about 850ºC and ambient pressure
• H2/He permeation testing at about 850ºC and higher pressures to 30
atmospheres
• H2/He permeation testing with H2/He and certain contaminants as H2S at
about 850ºC and higher pressures to 30 atmospheres
• Permeation testing with simulated biomass-derived syngas at about 850ºC
• Longer term durability testing with simulated biomass-derived syngas at
about 850ºC
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Technical Accomplishments and Progress: Permeation Testing with Simulated Biomass-Derived Syngas
• Thickness-100 microns
• Feed: 20%H2/80%He
• Syngas mixture composition:
20%H2, 20% CO,10% CO2,
10% H2O balance of He
• Feed pressure-30 atm
• Temperature – 850ºC
• Sweep gas- N2
02468
101214161820
0 2 4 6 8 10 12 14
H2
flux
, ccS
TP
/min
/cm
2
Time, hr
Syngasin
Syngasout
Almost no effect on hydrogen permeation
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Technical Accomplishments and Progress: Effect of H2S on Pd80Cu20 alloy Membrane
Sulfur tolerance at 750-850°C
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Technical Accomplishments and Progress:Testing of Porous Support for Mechanical Stability and Transport Resistance
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
0 20 40 60 80
H2
Flux
, ccS
TP/m
in/c
m2
Time, min
Membrane+SS support+ Cement
Membrane only
Ceramic, stainless steel and titanium porous substrates were tested for support structure.
SS porous support
• (20 µm in pore size)
• Coated by cement
• High mechanical stability
• No mass transfer resistance.
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Technical Accomplishments and Progress: Design of Membrane Module
Draft version of membrane module designed by GTI and reviewed by Wah Chang
A
A
A-A
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Technical Accomplishments and Progress: Catalysts for Tar Cracking, Reforming and Shift Reactions
CnHm + nH2O → nCO + (m/2+n)H2 Tar Decomposition
CH4 + H2O → CO2 + 3H2 Methane reforming
CO + H2O → CO2 + H2 Water-Gas Shift
Ni-based catalysts: deactivation, sintering, volatilization of nickel, carbon formation.
Solutions: use as “secondary”, steam addition, lower temperature, removal of hydrogen.
Conclusion: Tar cracking, reforming and water-gas shift reactions can be catalyzed by Ni-based catalyst. H2-selective membrane promotes reactions to higher degree of completion
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Technical Accomplishments and Progress:Gasification Membrane Reactor Process Development and Economic Analysis
• UGAS ™software is used to predict product composition from biomass gasifier.
• Downstream processes variations
Target: Biomass gasification membrane reactor technology will meet the DOE‘s cost target of $2.5/Kg H2.
Biomass,Oxygen/airT, P, etc
SyngascompositionUGAS™
softwareHYSYS™ software
Downstream processes
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Technical Accomplishments and Progress: Simplified Diagrams of Different Process Variations after Biomass Gasification
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Proposed Future Work
Continue to identify metal additives to enhance the catalytic activity of Pd-based alloys in the presence of sour gas-H2 S and chemical and mechanical stability of highly-permeable Pd-based alloys-NETL and GTI
Synthesis of Pd-containing glass-ceramic membranes-Schott
Process Development and Economic Analysis for different downstream processes after biomass gasification (“go/no-go” point)
Fabrication of membrane module integrated with biomass reactor
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Summary
> Project was initiated again (February 2010) after 1 year hiatus. Selected team members began contractual activities with GTI
> Initial candidate membrane was chosen and “go” decision was made
> Development of metallic, glass-ceramic membranes are in progress
> Process development and Economic analysis is in progress- go/no go point
> Membrane module design is in progress
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SummaryHydrogen Permeation Fluxes for Different Types of Membranes
Membrane CompositionHydrogen Flux Temperature ΔP H2
Effect of H2S Effect of Syngas
SCFH/FT2 (oC) psi
50Pd50Au 12.8 850 86.715% decrease n/a
80Pd20Cu 47.2 850 216.27% decrease n/a
80Pd20Cu 25.6 850 85.1n/a 7% decrease
75Pd25Ag 36.8 850 52.915% decrease 5% decrease
69Pd31Pt 24.5 750 79.318% decrease n/a
95Pd5Au 81.9 750 79.835% decrease n/a
77Pd23Ag 36.0 700 78.0n/a n/a
94Pd6Ni 40.5 750 79.6n/a n/a
80Pd20Cu 27.7 900 80.5n/a n/a
<1%Pd-glass 0.15 350 35.7n/a n/a
<1%Pd-glass 0.25 850 12.0n/a n/a
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Supplemental Slides
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Hydrogen Production Cost from Biomass Gasification
Total cost breakdown Capital cost breakdown
25%
25%
50%
feedstock
capital
operation & maintenance
20%
15%25%
20%20%
biomass feed handlinggasifierair separationreforming & separationbalance of plant
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Advanced Inorganic Membranes for Biomass Gasification Application
Hydrogen at high pressure e-
e-
H+
Mixed proton/electron conducting membrane
H2 2H+ +2e- 2H+ +2e- H2 H+
Hydrogen at low pressure
Hydrogen at high pressure e-
e-
H+
Mixed proton/electron conducting membrane
H2 2H+ +2e- 2H+ +2e- H2 H+
Hydrogen at low pressure
Hydrogen at e-
e-
H+
Atomic transport dense metallic membrane
H2 2H 2HH+
Hydrogen at low pressure
Hydrogen athigh pressure H-
H
H
H2 2H 2H H2 H
Hydrogen at low pressure
e-
e-
H+
Multi-phase ceramic/metal membrane
H+
Ceramic phase
Metallic phase
Active H2 transport layer
Catalytic support layer
Dense thin layer on porous support layer
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Technical Accomplishments and Progress: HYSYSTM Scheme of Downstream Processes for Membrane Closely-coupled to Gasifier
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Project Time Schedule
Task Name Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 Q10 Q11 Q12 Q13 Q14 Q15 Q16 Q13 Q14 Q15 Q16 Q13 Q14 Q15 Q16 Q17 Q181 Membrane Material Development1.1 Ceramic Membrane Synthesis and Testing1.2 Metallic Membrane Synthesis and Testing1.3 Composite Membrane Synthesis and Testing1.3.1 Glass-ceramic membrane development1.4 Select initial candidate membrane1.5 Select best candidate membrane1.6 Optimization of Selected Candidate Membranes2 Process Development & Economic Analysis3 Bench Scale Biomass Gasifier Design & Preparation4 Integrated testing of initial membrane with gasifier4.1 Membrane module design4.2 Membrane module fabrication4.3 Integrated testing with bench gasifier5 Integrated testing of best candidate membrane with gasifier5.1 Membrane module design5.2 Membrane module fabrication5.3 Integrated testing with bench gasifier6 Project Management & Reporting
year7-2013year 5-2011 year 6-2012year 1-2007 year 2-2008 year 3-2009 year 4-2010