dr faizan ahmad senior lecturer in chemical engineering ... · dr faizan ahmad senior lecturer in...
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DrFaizanAhmadSeniorLecturerinChemicalEngineering
SchoolofScienceandEngineeringTeessideUniversity,UnitedKingdom
Chemical Engineering Post Doc Yeungnam University, South Korea (2014-15) PhD Univeriti Teknologi Peronas, Malaysia (2009-13) MS Otto-von Guricke University, Magdeburg, Germany (2004-07) BSc (Engg) University of the Punjab, Pakistan (2000-04)
Track Record Over 20 peer-reviewed journal articles, over 15 conference contributions, 1 Patent filed, 2 Gold medals and1 silver medal in innovation exhibitions Research Interests Carbon capture Environment and Energy Membrane Technology Process Modelling and Simulation
AcademicBackground
Alignment of My Research Area and Workshop Topic
WasteManagement/
ResourceEfficiency
LowCarbonEconomy
CO2canberesourceratherthanwaste
How CO2 Can be Resource
Ref:CarbonDioxideCanBeAResourceRatherThanAWasteProduct,TheEnergyCollecNve,Feb.2014
MoAvaAon for Carbon Capture Technology
ClimateChange
Source:PeNtet.al.,Nature,2000
Coal76%
NG14%
Fueloil9%
Other1% H2
Power79%
NGSweet
Refineries6%
Cement7%
Steel5%
Petro.Chem.3%
MoAvaAon for CCS Technology Energy Profile
GlobalCarbonDioxideEmissionsfromPowerGenerationperyearTotal=10,539Mt
GlobalCO2EmissionsperyearTotal=13,375Mt
(60%oftotal)
Carbon Capture OpAons Technologies Overview
¡ Systems§ Pre-combusNon§ Post-combusNon§ Oxy-fuelcombusNon
¡ SeparaNontechnologies§ Solvents–aqueousaminesandsalts§ Membranes–polymeric§ Solidsorbents–zeolite,acNvatedcarbon§ Cryogenicprocesses§ ChemicalLooping(Calciumlooping)
Advantages of Membrane SeparaAon
HighEfficiency LowEnergyRequirements
EaseofOperaNon
MechanicallyRobust
LowCapitalandOperaNng
Cost
EnvironmentalFriendly
Projected Growth in Membrane Market Demand (USD)
220Million(2020)
90Million(2010)
30Million(2002)
Reference:
R.W.Baker,"FutureDirecNonsofMembraneGasSeparaNonTechnology," Industrial&EngineeringChemistryResearch,vol.41,pp.1393-1411,2002.
ClassificaAon and SelecAon of Membrane Module Tubular
Module Plate and Frame Module
Spiral Wound Module
Capillary Module
Hollow Fiber Module
Manufacturing cost (USD/m2)
50-200 100-300 30-100 20-100 5-20
Packing density(m2/m3)
Low Low Moderate Moderate High
Resistance to Fouling
Very good Good Moderate Good Poor
Parasitic pressure drops
Low Moderate Moderate Moderate High
Suitable for High pressure operation
Can be done with difficulty
Can be done with difficulty
Yes No Yes
Limitations to Specific Type of Membranes
No No No Yes Yes
Hollow Fiber Membrane Module
• Hollowfibermembranemoduleisemployedbymorethan80percentgasseparaNonfaciliNesinindustry
• CosteffecNveandHighestpackingdensityincomparisontoothermodules.
• Extremelyfinepolymerictubeshavingdiameterof50-200micron
• Hollowfibermembranemodulewillnormallycontaintensofthousandsofparallelfiberspocedatbothendsinepoxytubesheets
Ref: J. P. Montaya., Membrane Gas Exchange. 2010, Available: http://permselect.com/files/Using_Membranes_for_Gas_Exchange.pdf
Membrane Module Development
MembraneProperNes:Polyimide(Matrimid)Innerdiameteroffibers:250µm
Outerdiameteroffibers:400µmLengthoffibers:28cmNumberoffibers:5,15,20,30,50
Flow sheet of Gas PermeaAon TesAng Unit
Natural gas CH4 CO2 N2
Feed Vessel
Hollow Fiber Membrane Module
Static mixer
F
Flow meter
T
Thermocouple
P
Pressure guage
F
TPBackpressure
Regulator
Pressure guage Thermocouple
F
Flow meter
Flow meter
P T
Pressure guage Thermocouple
Infrared Analyzer
Flow controller
Data Acquisition System (Computer)
Compressor
Oven
Gas PermeaAon TesAng Unit (CO2 from Natural Gas)
Example of Research Findings (Effect of Module CharacterisAcs on Gas Processing Cost)
0,01
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0 100 200 300 400 500
GPC
(USD
/MSCFofprodu
ct)
Lengthoffibers(cm)
LowerconcentraNonfeed(10%CO2)
MediumconcentraNonfeed(40%CO2)
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0 5 10 15 20 25 30 35
GPC
(USD
/MSCFofprodu
ct)
Radiusoffiberbundle(cm)
LowerconcentraNonfeed(10%CO2)MediumconcentraNonfeed(40%CO2)HighconcentraNonfeed(70%Co2)
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0,01
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40 45 50 55 60 65
GPC
(USD
/MSCFofprodu
ct)
Porosity(%)
LowerfeedconcentraNon(10%CO2)MediumfeedconcentraNon(40%CO2)HigherfeedconcentraNon(70%CO2)
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0,01
0,02
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0 0,005 0,01 0,015 0,02 0,025 0,03
GPC
(USD
/MSCFofprodu
ct)
Outerdiameteroffiber(cm)
LowerfeedconcentraNon(10%CO2)
MediumfeedconcentraNon(40%CO2)
Comparison of Process Performance and Economics
0
0,005
0,01
0,015
0,02
0,025
0,03
0,035
0,04
0,045
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99,5
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GPC
(USD
/MSCFofprodu
ct)
Metha
nepurity
(%)
Radiusoffiberbundle(cm)
MethanePurity(%)
GPC(USD/MSCFofproduct)
Hybrid Membrane Processes
Hybridmembrane/disNllaNonprocess
Hybridmembrane/cryogenicprocess
Hybridmembrane/absorpNonprocess
Current Project: Process IntensificaAon Hydrogen on Teesside/North East England
• BACKGROUND
TheNorthEastisaworldleaderinthelargescalemanufactureofhydrogen,producingmorethan50%oftheUK'stotalinTeesValley.ArecentstudyoutlinesopportuniNestoincreasethisfurtherreaffirmingtheregion'sposiNonasthethirdlargesthydrogeneconomybehindLondonandAberdeen.
Tees Valley and North East Hydrogen Economic Study Final Report 16thOctober2014
GlobalTrends(fromWorldHealthOrganizaTon)- TheglobalurbanpopulaNonisexpectedtogrowbyapproximately1.7%peryearbetween2015and2030.- Currently>80%ofpeoplelivinginurbanareasthatmonitorairpolluNonareexposedtoairqualitylevels
thatexceedWHOlimits.- Accordingtothelatesturbanairqualitydatabase,98%ofciNesinlow-andmiddleincomecountrieswithmorethan100000inhabitantsdonotmeetWHOairqualityguidelines.
Making Hydrogen on Teesside
Hydrocarbon Feed
Steam
Shift Conversion
Steam Reforming
Sulphur Removal
PSAUnit
Product Hydrogen
Purge Gas to Steam Reformer Burners CnHm+nH2O=>nCO+((n+m)/2)H2
CH4+H2O<=>CO+3H2CO+H2O<=>CO2+H2
Althoughhydrogenfromnaturalgasiscertainlyaviablenear-termopNon,itisnotviewedbyDOEasalong-termsoluNonbecauseitdoesnothelpsolvethegreenhousegas(GHG)orenergysecurityissues.BUT……………………………………..ChickenandEgg,InvestorandConsumer
What is Process IntensificaAon
• LowerCost(CAPEX–OPEX)• Smallersize• HigherEfficiency• SaferDesign• Becershape• Combinedprocesscomponents• Sustainabledevelopment
AimsandobjecTves:i. Standalone(orhybrid)andsmallscale
(suitablefor1-5kWFuelCellapplicaNonsforsmallresidenNalheaNng)
ii. Demonstrated/ValidatedforoperaNonundersimulatedenvironments–uptoTRL5(TechnologyReadinessLevels)
iii. ProjectedCosteffecNvenesstobesuperiortoconvenNonalPressureSwingAdsorpNon
(Ref:"TechnologyReadinessAssessment(TRA)Guidance";UnitedStatesDepartmentofDefense.April2011.)
CurrentProject:TodevelopaninnovaTveHydrogenpurificaTontechnologybasedonmembranesystems,withthefollowingaimsandobjecTves–
ForExample:
IncorporaNngtheuseofMembranereactor/separatortechnology(source:PallCorporaNon)toproducepureHydrogenfromaconvenNonalNaturalGasReformaNonsetup
ReplacingtheWatergasShirreactorwithaWGSmembranereactortocombinereacNonandseparaNon/purificaNonofhydrogeninonemoduleitself–onestageofprocessintensificaNon
IncorporaNonofMembranereactoratthereformingstageitselftoinducemoreWGSduringthereformaNonitself,andyieldpureH2–ulNmateprocessintensificaNon
Making and using Hydrogen is happening
Making and using Hydrogen is happening
• BOCLindeinpartnershipwithDaimlertobuild13newhydrogenfuellingstaNonsinGermanybytheendof2015,tobesuppliedwithsustainablysourcedhydrogen.
• HeadofCleanEnergy&InnovaNonManagementatLinde.“WearemakingavaluablecontribuNontothesuccessfulcommercialisaNonoffuel-cellvehicleswhilesupporNnginiNaNvesliketheCleanEnergyPartnership(CEP)and‘H2Mobility’.”“ThereisnoquesNonthatfuel-celltechnologyisreachingmaturity.From2017,weareplanningtobringcompeNNvelypricedfuel-cellvehiclestomarket.SonowistheNmetobuildanaNonwidefuellinginfrastructure.TheaimistoenablemotoriststoreachanydesNnaNoninGermanyintheirhydrogenfuelledvehicles.ThisiniNaNveisahugestepforwardonthejourneytoatrulynaNonwideH2network,”statesProfessorHerbertKohler,VicePresidentGroupResearch&SustainabilityandChiefEnvironmentalOfficeratDaimlerAG.
Making and using Hydrogen is happening
Blending hydrogen into natural gas pipeline networks has also been proposed as a means of delivering pure hydrogen to markets, using separation and purification technologies downstream to extract hydrogen from the natural gas blend close to the point of end use. As a hydrogen delivery method, blending can defray the cost of building dedicated hydrogen pipelines or other costly delivery infrastructure during the early market development phase.
What is Process IntensificaAon
• LowerCost(CAPEX–OPEX)• Smallersize• HigherEfficiency• SaferDesign• Becershape• Combinedprocesscomponents• Sustainabledevelopment
AimsandobjecTves:i. Standalone(orhybrid)andsmallscale
(suitablefor1-5kWFuelCellapplicaNonsforsmallresidenNalheaNng)
ii. Demonstrated/ValidatedforoperaNonundersimulatedenvironments–uptoTRL5(TechnologyReadinessLevels)
iii. ProjectedCosteffecNvenesstobesuperiortoconvenNonalPressureSwingAdsorpNon
(Ref:"TechnologyReadinessAssessment(TRA)Guidance";UnitedStatesDepartmentofDefense.April2011.)
CurrentProject:TodevelopaninnovaTveHydrogenpurificaTontechnologybasedonmembranesystems,withthefollowingaimsandobjecTves–
ForExample:
IncorporaNngtheuseofMembranereactor/separatortechnology(source:PallCorporaNon)toproducepureHydrogenfromaconvenNonalNaturalGasReformaNonsetup
ReplacingtheWatergasShirreactorwithaWGSmembranereactortocombinereacNonandseparaNon/purificaNonofhydrogeninonemoduleitself–onestageofprocessintensificaNon
IncorporaNonofMembranereactoratthereformingstageitselftoinducemoreWGSduringthereformaNonitself,andyieldpureH2–ulNmateprocessintensificaNon
• UsingtheconceptofProcessIntensificaNonforproducNonofHydrogen,i.e.,mulN-funcNonalreacNonseparaNonsystems,tolowercapitalcosts;
• IntroducecomplexityandmulN-funcNonalityinthereactor–itismuchmoreeffecNvetodosoinsmallerscale,andhencetheapplicabilitytosmallersystems
• IntegratedmaterialsprocessingandcharacterizaNon,reactordesignandtesNng,moduleandprocessdesign
Approachtotheproblem
ImpureHydrogenorHydrogencontainingfeedstock,obtainedbyusingsmallscaleprocesses
Process ComposiTonoffeedstock OpTonsforHydrogenpurificaTonbyuseofmembranes
AnaerobicfermentaNonofBiomass
50-85%Methane;20-35%CO2;H2,O2,N2andH2Sinvaryingamounts,uptoafewpercent
1. Sulphurremoval(fromH2S)2. ReformaNonofMethanetosyngas3. WaterGasShir/HydrogenSeparaNon-
concentraNon
Hydrogenfrompipelines,caverns
Over99%Hydrogen,parNcles,dust,soils,S-odorant
OnlyMembraneassistedpurificaNon
Ref: Alberta Gas Ethylene Co. (AGEC) hydrogen pipeline (3.7 km in length) – The line currently carries 4,825 kg-mole/hr of 99.99% pure hydrogen at a maximum operating pressure of 5,790 kPa (57 bar) from the AGEC hydrogen purification plant to the Cominco Fertilizers/Alberta Energy Co. Ltd. plant.
Note:BydevelopingaprocessforgeneraLnghighpurityhydrogenfrombiomass,weareaddressingamorecomplexsystem;allotherpurificaLonmodulescanbesubsetsofthelargerproject
WorkBreakdownStructure(Workpackages)
1.ProcessConfiguraNon,ProcessDesignCalculaNonsforcomponentdesign
2.LaboratoryScaledevelopmentof‘selected’MembraneSystems
3.MeasurementofMembranePerformance
1.1IdenNfyarepresentaNveBiomassanaerobicdigesNonsystemassupplierforbiogas,toascertainexpectedcomposiNons,andimpurityconcentraNons;alsoidenNfyothersourcesofHydrogenlocally,whichrequirepurificaNonandarefeedstocksforPEMFCs–TU,withotherpartners1.2ProcessDesign–PFD,Mass-EnergyBalances,P&ID,anddetaileddesignofreactors,andpurificaNonsystems-TU1.3FabricaNonofmembrane-moduleassembly–Partners,Industry
2.1MembranesynthesistogenerateopNmalmorphology–TU,OtherUniversiNes/Labs(collaboraNve)2.2BasiccharacterizaNon–XRD,Surfacearea,microstructure(TU,OtherUniversiNes/Labs(collaboraNve)2.2Designofsuitable‘module’,andmembrane-moduleintegraNon(TU)
3.1PermeabilityexperimentsonsinglemembraneswithfocusonachievingselecNveexclusion/adsorpNonofCO2andotherimpuriNes,inbiogaswithhighthroughputofH2,closeto100%perm-selecNvity(TU)3.2.Membrane-ModuleTesNng(TUandPartners)3.3DegradaNonstudies,andmiNgaNonofflawsandimperfecNonsinthemembrane,membrane-moduleassembly(TUandPartners)
Reasonablelimitsforpressure–balancebetweenpermeabilityandpressure Reasonablelimitsforpermeabilitybasedon
pressuresensiNvity(above)–balancebetweenpermeabilityandmembranearea
PerformanceTargets• 99.99%hydrogenpurity• 90%recoveryofHydrogenfromfeed• FeedcomposiNonstobe>50%Hydrogen
MembraneModulea\ributes,baseduponcalculaTonsPermeability–1500GPUPressure–10-15barAreas–0.06to0.10m2
ProcessCalculaTonsfor50%Hydrogenfeed,5kg/day–esTmaTonofpermeability,area,andpressurerequirements
BaseduponsimilarcalculaNons,MembraneModuleacributescanbeprojected,andsuchnumberscanbeachievedbymaterialsandmoduledesignopNmizaNon
Research Areas for Partnership • PurificaNonofHydrogenusingmembraneforfuelcellapplicaNon(Cleanenergy)
• PurificaNonofbiogasasrenewableenergysourceusinghollowfibremembraneprocess
• HybridMembrane-AbsorpNonprocessforCO2Capture