WP6

DESIGN, DEVELOPMENT AND TEST OF THE PROOF -OF-CONCEPT PLANT 1 (ITALY: 2 kW CCHP, WWTU BIOGAS )

SOFCOM Meeting M24

Politecnico di Torino

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PREVIOUS WORK UNTIL M24

July 2013

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Executive project of the demonstration plant developed by an external company.

September 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 forniture to an external company

PLANT AREA (I)

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Tap water

Industrial water

Instrument air

Biogas

Drinking water

Discharge

PLANT AREA (II)

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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

• 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

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

Evaporator mixer

Reformer

IN

OUT

FUEL PROCESSING (III)

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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 interconnections.

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 will be insert here

OXY-COMBUSTOR(II)

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Porous SiC, layout 1

Porous SiC, layout 2

Catalytic oxy-combustor, water quenching required

OXY-COMBUSTOR (III)

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3 layout developed by IEN, 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 interconnection 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 (IV)

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Final hot-box layout

REFORMER

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 heating

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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Inlet connection

Compressor

Drypoint membrane

• 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 cylinder -from the demo plant

Waste water

PBR

Treated water

Algae

TANK

MEMBRANE

ALGAE WATER TREATMENT (II)

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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

INLET AND OUTLET STREAMS

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Biogas supply Total flow rate (Max/Nom/Min) – 14/13.96/8.3 SLPM Maximum concentration of solids – < 0.0001% Temperature (Max/Nom/Min) – 30/20/10°C Pressure (Max/Nom/Min) – 0.20/0.17/0.1 barg Typical composition of inlet biogas – CH4 (Max.) 65% vol. CO2 (Max.) 55% vol. H2O traces H2S traces (< 100 ppm) Siloxanes traces (1100 ppm)

Waste Water Total flow rate (Max/Nom/Min) – 250/164/150 L/h Temperature (Max/Nom/Min) – 30/20/5°C Pressure (Max/Nom/Min) – atm. Contaminants – N-NO3 10 mg/L P-PO4 1 mg/L

Treated Water Total flow rate (Max/Nom/Min) – 245/160/145 L/h Temperature (Max/Nom/Min) – 30/20/5°C Pressure (Max/Nom/Min) – atm. Contaminants – N-NO3 4.6 mg/L P-PO4 0.2 mg/L

Inle

t S

tre

am

s

Ou

tle

t S

tre

am

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 H2 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 Installed power – 20 kW

POWER SUPPLY (I)

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Power

Unit 400 V 230 V 24 V

PU-101 - Fuel Cleaning 0.0 0.0 0.0 kWe

PU-102 - Fuel Processor 0.0 6.0 0.5 kWe

PU-103 - SOFC 0.0 4.9 0.0 kWe

PU-104 - Oxy-Combustor 0.0 1.0 0.3 kWe

PU-105 - Condenser 0.0 0.7 0.1 kWe

PU-106 - Photobioreactor 6.0 0.0 0.1 kWe

Demonstration Plant

Equipment Power @ 400 V 6.00 kWe

Equipment Power @ 230 V 12.60 kWe

Control System and Auxiliaries @ 24 V 1.14 kWe

Losses (estimate) 0.70 kWe

Total Power (estimate) 20 kWe

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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November/Dicember 2013

• Demonstration plant installation

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

January/February 2013 • Installation and start-up of the

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

March/August 2013 • Start-up and operation period

(6 month) of the overall demo plant

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Any question?

Marta Gandiglio Andrea Lanzini Massimo Santarelli