Status, progress and next steps of WP6

D E S I G N , D E V E L O P M E N T A N D T E S T O F

T H E P R O O F - O F - C O N C E P T P L A N T 1 ( I T A L Y : 2 k W C H P , W W T U B I O G A S )

SOFCOM Mid Term Review

SOFCOM WP6

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Key objectives of the DEMO in Torino (IT)

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The main general objective of SOFCOM DEMO unit in Torino (IT) is to demonstrate

the high interest of electrochemical systems based on high temperature fuel cells

to operate as the core of future energy systems with renewable fuels and

multi-product configuration, featuring also a CO2 recovery through re-utilization of

the C and H atoms inside the system using different processes (electrochemical,

chemical, biological as in SOFCOM).

DEMO 1 Torino (IT): field demonstration of WWTU biogas-fed SOFC with CO2

recovery and reuse; real operating environment.

The first proof-of-concept SOFC system is able to operate with biogas produced in

an industrial waste water treatment unit (WWTU). The plant will be in operation as

CHP plant, with heat recovery from the exhaust for the production of hot services

(hot water). Also, the plant will be completed with a with a section of CO2 recovery

for Carbon reutilization in a photo-bio-reactor for C storage in form of algae (CO2

sink).

DEMO: WWTU-SOFC-CO2 recovery: overall structure of the DEMO

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BIOGAS from SMAT digesters fed by secondary treatment sludges of the WWTP.Biogas:60% CH4 – 40% CO2

Two CLEANING VESSELS:• H2S removal

=> ZnO • Siloxanes removal

=> Activared Carbon• 14 SLPM biogas

FUEL PROCESSING UNIT• Steam reforming (demi

water from demineralizer)• Evaporator Mixer• Reformer (S/C = 2)• Reformer Temp. = 750 °C

SOFC Stack• 2 kWe• 90 cells, 3YSZ• SOFC Temp = 800 °C.• Inlet fuel Temp = 750 °C.• Inlet air Temp = 650 °C.

AIR PRE-HEATER• Inlet air pre-heated

through a mixed exhaust recuperator/electrical heater.

• Cathode exhaust used for CHP (water heating). CO2 SEPARATION UNIT

• Water condenser• Compressor up to 5 bar• Pressurized membrane

stage => H2O < 500 ppm

WASTE WATER TREATMENT VIA ALGAE GROWTH3 PBR modules (9 m2)Algae production 8 gdry/hOutlet streams: • Treated water (reduced N/P compounds)• Algae (to digesters)

POWER

HEAT

HEAT

ALGAE

DEMO: WWTU-SOFC-CO2 recovery: GANTT

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N TASK 15 18 21 24 27 30 33 36

6,1 Biogas production

6,2 Biogas cleaning system

6,3 Biogas processing system

6,4 SOFC CCHP system

6,5

O2 separation and anode

exhaust catalytic burner

6,6

CO2 separation from anode

exhaust

6,7

CO2 management and disposal

system

6,8 Testing of the complete system

6,9

Monitoring of the complete

system in the long run

YEAR 2 YEAR 3

PREVIOUS WORK UP TO M24

July 2013

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Detailed design of the demonstration plant.

August 2013

Deliverable 6.12 « Detailed blueprint of the demonstration of integrated system WWTU biogas + SOFC in Torino”

October 2013 SMAT: assignment of the installation and material/accessories supply to an external company

PLANT AREA (I)

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SMAT WWTU Plant, Torino (IT): serves over 2 million population equivalents in the metropolitan area of Torino treating over 620.000 cubic meters per day of waste water, with a production of 33000 Nm3/day biogas

PLANT AREA (II)

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Tap water

Waste water

Instrument air

Biogas

Service water

Drain

PLANT AREA (III)

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Demonstration plant

Oxygen

Nitrogen

Carbon Dioxide

Hydrogen

Photobioreactor

Control Room

Shed

DEMONSTRATION PLANT

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SOFCOM Demo Plant Units

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Cleaning Unit

Reforming Unit

SOFC Stack Unit

Oxy-combustor

CO2 separation Unit

Algae Water Treatment

CLEANING UNIT (I)

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Inlet biogas from SMAT max. 14 SLPM 100 ppm H2S 1100 ppb siloxanes

N2 for bed substitution 2 SLPM/month Clean biogas to

the reformer

CLEANING VESSELS

CLEANING UNIT (II)

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• Outside diameter 88 mm • Inside diameter 85 mm

• Height

1. ZnO: 30 cm 2. SiC: 5 cm 3. ZnO: 30 cm

• Particle size

• ZnO: 4.5 mm • SiC: 1.3 mm

Clariant catalyst ActiSorb S2 (G-72 D)

• Outside diameter 88 mm • Inside diameter 85 mm • Height

1. AC: 30 cm 2. SiC: 5 cm 3. AC: 30 cm

• Particle size: • AC: 4.5 mm • SiC: 1.3 mm

Norit RST3, steam activated carbn

H2S adsorber Siloxane adsorber

SOFCOM Demo Plant Units

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Cleaning Unit

Fuel Processing

SOFC Stack Unit

Oxy-combustor

CO2 separation Unit

Algae Water Treatment

FUEL PROCESSING (I)

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Reformate to SOFC stack

H2 for stand-by

N2 for start-up and stand-by

Demi water from Demineralizer + atmospheric tank (SMAT)

Biogas from cleaning

REFORMER

PUMP+PRESSURIZED TANK

To SOFC

To Reformer VENTING

FUEL PROCESSING (II)

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Mixed steam+dry reforming

Ni-based catalyst:

Commercial catalyst composed of 20wt% of Ni supported on -Al2O3 (63wt%) and CaO (5.5 wt%) mixture

Catalytic activity suffers the presence of sulfur compounds in the inlet gas stream (H2S conc. ≥0.4 ppm); while the presence of hydrocarbon compounds (conc. 200 ppm) and siloxane (D5 conc. <1 ppm) result less harmful.

0

20

40

60

80

100

0 20 40 60 80 100

CH

4C

on

ve

rsio

n (

%)

Time (h)

H2S = 2 ppm

H2 S= 1,6 ppm

H2S = 1 ppm

H2S = 0,4 ppm

H2S poisoned biogas steam reforming test (CH4/CO2=55/45%vol.) H2O/CH4=2 mol/mol; GHSV=10,000 h-1; T=1073K; p= 1bar

FUEL PROCESSING (III)

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Inlet connections for: • Biogas • Demi water • H2/N2

Evaporator mixer

Reformer

IN

OUT

FUEL PROCESSING (IV)

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Evaporator inlet

Reformer outlet

N2 and H2 MFC

Demi water MFC

Component/Unit Operation H2 [SLPM] N2 [SLPM]

Processing (CNR) Start-up/Shut-down 0.0 16.7

Stand-by 1.2 11.2

SOFCOM Demo Plant Units

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Cleaning Unit

Fuel Processing

SOFC Stack Unit

Oxy-combustor

CO2 separation Unit

Algae Water Treatment

SOFC STACK UNIT (I)

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N-H mix for Start-up and stand-by => N-H mix from the reformer MFC

Reformate

Cathode air

Tap water for CHP

Anode exhaust

Cathode exhaust

Tap water for CHP

SOFC

AIR PRE-HEATER

HX CHP

BLOWER

SOFC STACK UNIT (II)

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SUNFIRE® SOFC Stack 2 kWe 90 cells, 3YSZ SOFC working temperature = 800 °C. Inlet fuel temperature = 750 °C. Inlet air temperature = 650 °C.

Component/Unit Operation H2

[SLPM] N2

[SLPM]

SOFC Stack (POLITO) Start-up/Shut-down 3.0 57.0

Stand-by 20.1 30.1

SOFC STACK UNIT (III)

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DOMEL® Brushless blower for cathode air up to 300 mbar

FACO® CHP recuperator from cathode exhaust (340 - 90 °C)

SOFC UNIT (IV)

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SUNFIRE® Air recuperator (from ambient to 550°C). Air electrical heater (from 550 to 650°C).

Fixed connection between the SOFC stack and the air pre-heater Development of a common layout with reformer and oxy-combustor partners in order to avoid interferences.

SOFCOM Demo Plant Units

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Cleaning Unit

Fuel Processing

SOFC Stack Unit

Oxy-combustor

CO2 separation Unit

Algae Water Treatment

OXY-COMBUSTOR (I)

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Oxygen

Anode exhaust

Cooling air

Tap water for cooling

OXY-COMBUSTOR

Cooling air

Anode exhaust

Tap water for cooling

COOLER

A venting is inserted here

OXY-COMBUSTOR (II)

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oxy-combustor: operation in high temperatures, in range 700-800°C

ability to burn lean mixtures of gases composed mainly of H2 (15%max) CO (7%max), CO2, H2O

very efficient operation i.e. mole fraction of unburned H2 and CO < 0.2 %

pressure drop of the gases from SOFC stack on the burner should be lower than 20 mbar

silicon carbide (SiC) porous foam (porosity 0.86)

air-cooled

inlet oxgen from cylinders

water cooler at combustor outlet until 77°C.

OXY-COMBUSTOR (III)

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Porous SiC, layout 1

Porous SiC, layout 2

Catalytic oxy-combustor, water quenching required

OXY-COMBUSTOR (IV)

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3 layout developed by IEN, one still under testing The porous oxy-combustor (layout 1 and 2 have the same dimensions) has been chosen and used for the demonstration plant blueprint because: - It can be placed horizontal => Shorter connection pipe with the stack outlet.

- It does not require water quenching => Smaller amount of demi water from the

demineralizer.

Final hot-box layout

OXY-COMBUSTOR (V)

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Final hot-box layout

REFORMER

SOFC STACK

POROUS OXY-COMBUSTOR

AIR PRE-HEATER

Inlet and outlet connections from the stack will only require insulation due to short interconnection pipes. => NO electrical tracing

SOFCOM Demo Plant Units

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Cleaning Unit

Fuel Processing

SOFC Stack Unit

Oxy-combustor

CO2 separation Unit

Algae Water Treatment

CO2 SEPARATION (I)

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Anode exhaust

Air for the cooling fan

Tap water

CONDENSER

MEMBRANE

CMP

Tap water

CO2

CO2 SEPARATION (II)

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Condenser unit.

Compressor up to 8 bar.

Membrane separator (BEKO Technologies type 08-28A Drypoint M Plus) 100% CO2 (H2O 500 ppm)

with purge gas recirculation

MembranMembran

From Oxy-Combustor

Wet purge gas

Dry process gas

Needle valve for purge gas

adjustment

Mixing with purge gas

CO2 SEPARATION (III)

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Inlet connection

Compressor

Drypoint membrane

• Final check tests on November 2013 • Shipping to POLITO on Dicember 2013

SOFCOM Demo Plant Units

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Cleaning Unit

Fuel Processing

SOFC Stack Unit

Oxy-combustor

CO2 separation Unit

Algae Water Treatment

ALGAE WATER TREATMENT (I)

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CO2 - from the demo plant - from cylinder

Waste water

PBR

Treated water

Algae

TANK

MEMBRANE

ALGAE WATER TREATMENT (II)

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Inlet streams:

waste water (10 mg N/l + 1 mg P/l)

CO2 (dissolved concentration before inhibition 550 ppm)

Outlet streams: treated water, O2 and CO2 vented, algae purge.

Algae production: 20 g/m2/day (0.77 g/l/day)

ALGAE WATER TREATMENT (III)

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Photobioreactor

Pumps, tank and membrane placed behind the PBR

EQUIPMENT LIST

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P&ID of the plant units

Equipment list with required items and supply partner

Auxiliary services definition and requirement calculation

Power Supply calculation

Control system definition

Demonstration plant layout drawing

AUXILIARY SERVICES (I)

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Nitrogen

N2 users: - Cleaning Unit (bed substitution – once a month) - Fuel Processor (start-up and stand-by) - SOFC (start-up and stand-by) => mixed with H2 in the

Processing Unit - Emergency

Parameter Max Nom Min

Total flow rate [NLPM] 57 30 2

Available temperature [°C] 30 20 10

Available pressure [barg] - 16 -

AUXILIARY SERVICES (II)

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Hydrogen

H2 users: - Fuel Processor (stand-by) - SOFC (start-up and stand-by) => mixed with N2 in the

Processing Unit

Parameter Max Nom Min

Total flow rate [NLPM] 20 20 0

Available temperature [°C] 30 20 10

Available pressure [barg] - 16 -

AUXILIARY SERVICES (III)

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O2 users: - Oxy-combustor (continuous flow rate during

operation)

Parameter Max Nom Min

Total flow rate [NLPM] 4.39 3.07 2.05

Available temperature [°C] 30 20 10

Available pressure [barg] - 16 -

Oxygen

AUXILIARY SERVICES (IV)

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CO2 users: - Photobioreactor (used when the demo plant is not feeding the

PBR).

Parameter Max Nom Min

Total flow rate [NLPM] - 0.0205 -

Available temperature [°C] 30 20 10

Available pressure [barg] - 16 -

Carbon dioxide

AUXILIARY SERVICES (V)

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Demi water Demi water users:

- Fuel Processor (continuous flow during reformer operation). Demi water stored in pressurized tank.

Parameter Max Nom Min

Total flow rate [NLPM] 0.715 0.715 -

Available temperature [°C] 30 20 10

Available pressure [barg] - - -

AUXILIARY SERVICES (VI)

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Tap water

Tap water users: - SOFC Unit (tap water for the CHP heat-exchanger) - Oxy-combustor (tap water used for exhaust cooling) - CO2 separation (tap water used in the condenser)

Parameter Max Nom Min

Total flow rate [NLPM] 1078 1078 -

Available temperature [°C] 30 20 10

Available pressure [barg] 3 2 1

AUXILIARY SERVICES (VII)

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Waste water

Waste water - Photobioreactor (continuous flow during PBR operation)

Parameter Max Nom Min

Total flow rate [NLPM] - 4.17 -

Available temperature [°C] 30 20 10

Available pressure [barg] 3 2 1

AUXILIARY SERVICES (VIII)

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Instrument air users: - Pneumatic Valves

Pressure = 4 barg Filtered and oil free (Max. oil content 0.003 ppm; max dust content 0.01 μm) Dehumidified (Dew point 20 °C max.)

Instrument air

POWER SUPPLY (I)

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Line 1 – 400 V AC Line 2 – 230 V DC

CONTROL SYSTEM

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Starting from the data about the control system related to each single unit (partner supply), the overall signals list with estimation of the un-completed issued concerning the control system and consequently the operation of the plant, has been made.

DEMO PLANT LAYOUT (I)

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Detailed sizing (IEN+POLITO) of the connection between oxy-combustor and cooler to reduce the stream temperature before the HX (AISI 304) => pipe length = 1 m

DEMO PLANT LAYOUT (II)

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Air pre-heater

Air CHP

Reformer

SOFC

Cleaning system

Oxy-combustor

Cooling

CO2 separation

DEMO PLANT LAYOUT (III)

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FUTURE DEADLINES

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December 2013

• Demonstration plant installation

• Start-up of the first 3 units (Cleaning + Reformer + SOFC)

January 2014 • Installation and start-up of the

second 3 units (Oxy-combustor + CO2 separation +PBR)

March/August 2014 Start-up and operation period (6 month) of the overall demo plant

February 2014 • Complete assembly of the DEMO

DEMO: WWTU-SOFC-CO2 recovery: Deliverables

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Deliverable Number

Deliverable Title Lead benefi-ciary number

Estimated indicative person-months

Nature Dissemi-nation level

Delivery date

D6.1 Basic design for a biogas cleaning system for a first proof-of-concept SOFC system in Torino

2 1 R PU M18

D6.2 Installation and operation of the biogas production system

4 20 D RE M21

D6.3 Installation and operation of the biogas cleaning system

2 1 D RE M21

D6.4 Installation and operation of the biogas processing system

6 10 D RE M21

D6.5 Installation and operation of the SOFC CCHP system

1 30 D RE M21

D6.6 Installation and operation of the O2 separation and anode exhaust catalytic burner

7 2 D RE M24

D6.7 Installation and operation of the CO2 separation from anode exhaust

9 1 D RE M24

D6.8 Installation and operation of the CO2 management and disposal system

5 10 D RE M24

D6.9 Analysis of the specific test session on the complete system

1 27 R PU M33

D6.10 Analysis of the monitoring on the complete system on the long run

1 21 R PU M36

D6.11 Analysis of all the repair and maintenance activities developed on the complete system

4 26.5 R PU M36

Total 149.5

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Any question?

Marta Gandiglio Andrea Lanzini Massimo Santarelli