liquid fuels and electricity from it-fuel cells library/events/2015/2015sofc/willman.pdf · liquid...
TRANSCRIPT
Liquid Fuels and Electricity from IT-Fuel Cells
Carl A. Willman
16th Annual SOFC WorkshopPittsburgh, PAJuly 16th, 2015
Objective
Project Objective:To develop a cell technology capable of direct conversion of methane to liquid product, methanol or formaldehyde, by electrochemical partial oxidation at intermediate temperatures (<500°C), to provide means for an economic utilization of stranded gas.
Value Proposition
Western ND
Population ~100,000
Eastern NY, CT, MA & RIPopulation~25,000,000
Image – NASA Earth Observatory
Electrochemical Gas-to-Liquid (EC-GTL) offers a cost effective method forreducing emissions impact of strandedgas sourcesScalability, modular nature, andtransportability of electrochemicalsystem also provide the means toeconomically utilize associated gas atlow production wellheadsThe EC-GTL technology will meetARPA-E’s Mission Areas:
Enhance the economic and energysecurity of the United StatesEnsure that the United Statesmaintains a technological lead indeveloping and deploying advancedenergy technologies
Satellite image of visible light sources in US, demonstrating level of natural gas flaring
Concept
O2-
AIR
CH4CH3OH, HCHO, H2O
LOAD
Electrocatalyst OxidationMOγ+δO2- MOγ+δ +2δe-
Fuel FormationMOγ+δ + δCH4 δCH3OH + MOγ
MOγ+δ + δCH4 δ/2 HCHO + Moγ + δ/2 H2O
Redox Anode
Ceramic or NiO(Li) Cathode
Electrolyte
2 e-
Electrochemical Gas-to-liquid cell utilizes a metal/metal oxide redox couple, which serves as the anode electrocatalyst, to partially and indirectly oxidize CH4 to CH3OH and HCHO.
Partners
University of Connecticut – Cell manufacturingtechnology developmentPacific Northwest National Laboratory – GTL catalystdevelopmentEnergy and Environmental Research Center at theUniversity of North Dakota – GTL catalyst evaluation andpressurized testingMassachusetts Institute of Technology – Electrodeinterface characterization
Development Approach
Development of a novel EC-GTLcell presents an opportunity fortop-down approachIncorporation of the catalyst withinthe EC-GTL anode requires abilityto withstand constant redox cyclingChosen cathode and electrolytemust provide sufficient electrodeactivity and O2- ionic conductivityto support the Redox reaction withthe EC-GTL anodeInstitutional experience with MCFCcommercialization can beleveraged to facilitate pathway tocommercialization
SEM micrograph of potential EC-GTL cell under development at
FCE
Cell Materials - Support
Initial investigation focused onmodified NiO as cathode sidesupport, including productionline MCFC cathode, but wasfound to have insufficientmechanical strengthAnode side ceramic supportwas chosen, with desirableconductivity and mechanicalproperties
SEM micrograph of ceramic anode support with functional layer and
electrolyte
Cell Manufacturing
To reduce future cell cost and streamlinecommercialization, advanced manufacturingtechniques, that can be readily scaled to highvolume are being investigated as primarysource of laboratory sample testingReactive Spray Deposition Technology(RSDT) is employed to produce cellfunctional layers, in both porous and denseforms, with minimal to no post depositionprocessing/sintering required
Economically viable RSDT for fabrication of the EC-GTL cell components and
thin film layers
GTL Catalyst Development
Development of GTL catalyst that favorsthe production of methanol/al with highselectivity as opposed to reformation tohydrogenCatalyst selection using candidatematerials tested in batch-reactor modeOver twenty catalyst compositions havebeen evaluated, with multiple promisingcandidates identifiedPromising catalysts, based on selectivityand activity in ideal cell operation range, tobe incorporated into button cells, thenlarge area anodes
Batch mode reactor for catalyst evaluation.
GTL Catalyst Development
Catalyst screening has identified candidates with promising selectivity over desired range of temperatures
Less than 1% CO observed, no CO2
>90% Selectivity up to 600 °CContinued development will focus onincreased activity and conversion, whilepreserving selectivity
EC-GTL System ModelingSystem Process Flow Sheet Identifying the balance-of-plant processingrequirements developedPerformed system simulations based on thermodynamics first principlemethodsFocus on low-volume (~100 MCFD) associated gas systemsCost estimate based on prior fuel cell system development
Results of the System AnalysisBasis: One Barrel Per Day (BPD) of
Methanol ProductionRaw Gas Input 3.0 MCFDCell Area 12.5 M2
Gross DC Power 12.48 kWPlant Parasitic Loads 0.90 kWNet AC Power Output 10.9 kW
IT-GTL System
IT-GTL Anode
IT-GTL Cathode
Fresh AirBlower
Nat Gas
Exhaust
CatalyticOxidizer
Desulfurizer
AnodeRecycleBlower
Suplemenary Water
Air
Cathode Air Preheater
IT-GTL Module
Oxidant-side Process LoopFuel-side Process Loop
Anode HRU
Liquid Product
Separation
Liquid Product
EC-GTL System Cost
PILOT EC-GTL SYSTEM ANNUAL OPERATING COST
ANNUAL OPERATING COST ITEMSFUEL CELL STACK REPLACEMNT(3 RPLCMNTS) $ 11,459
FUEL (FLARED GAS) 0FUEL DESULFURIZER (10% UNIT COST) $ 29,883
SYSTEM OPERATION(O&M)2 TECHS ,$50/HR, 2200HR/YR) $ 220,000
TOTAL $ 261,342
ANNUAL REVENUES
POWER SALE (486.4 KW) (6 CENTS/KWHR) $ 229,050
METHANOL SALES (1.14GPM)($1.33/GAL) $ 716,909 TOTAL $ 945,959
ANNUAL COSTANNUALIZED CAPITAL COST @ 8% $ 173,000 ANNUAL OPERATING COST $ 261,342 ANNUALIZED INSTALLATION COST $ 153,000
TOTAL $ 587,342
PAYBACK PERIOD, YRSANNUAL COST/REVENUES 0.62
RATE OF RETURN,% ANNUAL REVENUES - 21%ANNUAL COST/INITIAL COST
Case Study for 40 BPD Plant
Cell performance assumptionsbased on end of project milestonesEquipment and Stack costestimated based on SOFCsystems of comparable scaleGas composition based on Bakkenassociated gas
Results
Material selection – parallel path developmentof multiple cell designs show promise to meetproject performance milestonesFabrication – RSDT parameters have beenrefined to new material sets to deposit layerswith desired characteristicsCatalyst development – Multiple catalysts haveshown very high selectivity to desired productsSystem analysis has shown the EC-GTL hasthe potential of co-generating 10 kw netelectricity while producing one Barrel ofmethanol per day (BPD), with promisingeconomics
RSDT Fabricated Anode Functional Layer for EC-
GTL cell
Future Plans
Continued development of GTL catalystIncorporation of GTL catalyst to anode layer forelectrochemical evaluationContinued fabrication development of RSDT formaterialsRefined Techno-economic analysis with actualcell performance
Acknowledgements
DOE/ARPA-E: Ping Liu, John Lemmon, John Tuttle, Mark PouyPNNL: Olga A. MarinaEERC: Ted AulichUCONN: Radenka Maric, Mark Aindow, Na LiMIT: Bilge YildizFCE: Hossein Ghezel-Ayagh, Alireza Torabi, Mick Barton, RobertSanderson