Thermodynamic analysis and techno-economic assessment of synthetic natural gas production via ash agglomerating fluidized bed gasification using coal as fuel

Implementing coal to synthetic natural gas (SNG) is a key way to deal with the conflict between supply and demand of natural gas in China. For the coal to SNG process, gasification is a crucial unit, which determines the syngas composition and influences cost of coal to SNG system. In this current study, a coal to SNG system using ash agglomerating fluidized bed gasification is designed and modeled. According to the above results, the thermal performance and technoeconomic assessment of the coal to SNG system are performed. The research demonstrates that exergy efficiency and energy efficiency of the whole system are 55.37% and 61.50%, respectively. Additionally, the results of the economic evaluation show that the SNG production cost is 1.87 CNY/Nm³ with a coal price of 250 CNY/t and an electricity price of 0.65 CNY/kWh. Sensitivities to variables such as water price, electricity price, total equipment cost and coal price are performed. Coal price represents the most important sensitivity, but the sensitivity to water price is relatively small.     

Technoeconomic analysis of a methanol plant based on gasification of biomass and electrolysis of water

Methanol production process configurations based on renewable energy sources have been designed. The processes were analyzed in the thermodynamic process simulation tool DNA. The syngas used for the catalytic methanol production was produced by gasification of biomass, electrolysis of water, CO₂ from post-combustion capture and autothermal reforming of natural gas or biogas. Underground gas storage of hydrogen and oxygen was used in connection with the electrolysis to enable the electrolyser to follow the variations in the power produced by renewables. Six plant configurations, each with a different syngas production method, were compared. The plants achieve methanol exergy efficiencies of 59–72%, the best from a configuration incorporating autothermal reforming of biogas and electrolysis of water for syngas production. The different processes in the plants are highly heat integrated, and the low-temperature waste heat is used for district heat production. This results in high total energy efficiencies (∼90%) for the plants. The specific methanol costs for the six plants are in the range 11.8–25.3 €/GJ_exergy. The lowest cost is obtained by a plant using electrolysis of water, gasification of biomass and autothermal reforming of natural gas for syngas production.     

Exergy analysis of biomass-to-synthetic natural gas (SNG) process via indirect gasification of various biomass feedstock

This paper presents an exergy analysis of SNG production via indirect gasification of various biomass feedstock, including virgin (woody) biomass as well as waste biomass (municipal solid waste and sludge). In indirect gasification heat needed for endothermic gasification reactions is produced by burning char in a separate combustion section of the gasifier and subsequently the heat is transferred to the gasification section. The advantages of indirect gasification are no syngas dilution with nitrogen and no external heat source required. The production process involves several process units, including biomass gasification, syngas cooler, cleaning and compression, methanation reactors and SNG conditioning. The process is simulated with a computer model using the flow-sheeting program Aspen Plus. The exergy analysis is performed for various operating conditions such as gasifier pressure, methanation pressure and temperature. The largest internal exergy losses occur in the gasifier followed by methanation and SNG conditioning. It is shown that exergetic efficiency of biomass-to-SNG process for woody biomass is higher than that for waste biomass. The exergetic efficiency for all biomass feedstock increases with gasification pressure, whereas the effects of methanation pressure and temperature are opposite for treated wood and waste biomass.     

Exergy analysis of hydrogen production plants based on biomass gasification

Biomass gasification is a promising option for the sustainable production of hydrogen rich gas. Five different commercial or pilot scale gasification systems are considered for the design of a hydrogen production plant that generates almost pure hydrogen. For each of the gasification technique models of two different hydrogen production plants are developed in Cycle-Tempo: one plant with low temperature gas cleaning (LTGC) and the other with high temperature gas cleaning (HTGC). The thermal input of all plants is 10 MW of biomass with the same dry composition. An exergy analysis of all processes has been made. The processes are compared on their thermodynamic performance (hydrogen yield and exergy efficiency). Since the heat recovery is not incorporated in the models, two efficiencies are calculated. The first one is calculated for the case that all residual heat can be applied, the case with ideal heat recovery, and the other is calculated for the case without heat recovery. It is expected that in real systems only a part of the residual heat can be used. Therefore, the actual value will be in between these calculated values. It was found that three processes have almost the same performance: The Battelle gasification process with LTGC, the FICFB gasification process with LTGC, and the Blaue Turm gasification process with HTGC. All systems include further processing of the cleaned gas from biomass gasification into almost pure hydrogen. The calculated exergy efficiencies are, respectively, 50.69%, 45.95%, and 50.52% for the systems without heat recovery. The exergy efficiencies of the systems with heat recovery are, respectively, 62.79%, 64.41%, and 66.31%. The calculated hydrogen yields of the three processes do not differ very much. The hydrogen yield of the Battelle LTGC process appeared to be 0.097 kg (kg_{(dry biomass)})⁻¹, for the FICFB LTGC process a yield of 0.096 kg (kg_{(dry biomass)})⁻¹ was found, and for the Blaue Turm HTGC 0.106 kg (kg_{(dry biomass)})⁻¹.     

Exergy analysis of synthetic natural gas production method from biomass

The paper presents the results of exergy analysis for a biomass-to-synthetic natural gas (SNG) conversion process. The presented study is based on wood gasification, which is analysed for different gasification conditions like temperature and/or pressure. The analysed temperature was varied in the range from 650 to 800 °C and the pressure range was from 1 to 15 bar. The main process units of biomass-to-SNG conversion technology are gasifier, gas cleaning, synthesis gas compression, CH₄ synthesis and final SNG conditioning. The results showed that the largest exergy losses take place in the biomass gasifier, CH₄ synthesis part and CO₂ capture unit. The overall exergetic efficiency of the biomass-to-SNG process was estimated in the range of about 69.5–71.8%.     

Thermodynamic analysis of a multigeneration system using solid oxide cells for renewable power-to-X conversion

A hybrid renewable-based integrated energy system for power-to-X conversion is designed and analyzed. The system produces several valuable commodities: Hydrogen, electricity, heat, ammonia, urea, and synthetic natural gas (SNG). Hydrogen is produced and stored for power generation from solar energy by utilizing solid oxide electrolyzers and fuel cells. Ammonia, urea, and synthetic natural gas are produced to mitigate hydrogen transportation and storage complexities and act as energy carriers or valuable chemical products. The system is analyzed from a thermodynamic perspective, the exergy destruction rates are compared, and the effects of different parameters are evaluated. The overall system's energy efficiency is 56%, while the exergy efficiency is 14%. The highest exergy destruction occurs in the Rankine cycle with 48 MW. The mass flow rates of the produced chemicals are 0.064, 0.088, and 0.048 kg/s for ammonia, urea, and SNG, respectively.     

Decentralized generation of electricity with solid oxide fuel cells from centrally converted biomass

A thermodynamic evaluation of different energy conversion chains based on centralized biomass gasification and decentralized heat and power production by a solid oxide fuel cell (SOFC) has been performed. Three different chains have been evaluated, the main difference between the chains is the secondary fuel produced via biomass gasification. The secondary fuels considered are hydrogen, synthetic natural gas (SNG) and syngas. These fuels are assumed to be distributed through a transport and distribution grid to the micro-combined heat and power (μ-CHP) systems based on a SOFC and a heat pump.     

Biomass gasification in district heating systems – The effect of economic energy policies

Biomass gasification is considered a key technology in reaching targets for renewable energy and CO₂ emissions reduction. This study evaluates policy instruments affecting the profitability of biomass gasification applications integrated in a Swedish district heating (DH) system for the medium-term future (around year 2025). Two polygeneration applications based on gasification technology are considered in this paper: (1) a biorefinery plant co-producing synthetic natural gas (SNG) and district heat; (2) a combined heat and power (CHP) plant using integrated gasification combined cycle technology. Using an optimisation model we identify the levels of policy support, here assumed to be in the form of tradable certificates, required to make biofuel production competitive to biomass based electricity generation under various energy market conditions. Similarly, the tradable green electricity certificate levels necessary to make gasification based electricity generation competitive to conventional steam cycle technology, are identified. The results show that in order for investment in the SNG biorefinery to be competitive to investment in electricity production in the DH system, biofuel certificates in the range of 24–42 EUR/MWh are needed. Electricity certificates are not a prerequisite for investment in gasification based CHP to be competitive to investment in conventional steam cycle CHP, given sufficiently high electricity prices. While the required biofuel policy support is relatively insensitive to variations in capital cost, the required electricity certificates show high sensitivity to variations in investment costs. It is concluded that the large capital commitment and strong dependency on policy instruments makes it necessary that DH suppliers believe in the long-sightedness of future support policies, in order for investments in large-scale biomass gasification in DH systems to be realised.     

Decentralized generation of electricity from biomass with proton exchange membrane fuel cell

Biomass can be applied as the primary source for the production of hydrogen in the future. The biomass is converted in an atmospheric fluidized bed gasification process using steam as the gasifying agent. The producer gas needs further cleaning and processing before the hydrogen can be converted in a fuel cell; it is assumed that the gas cleaning processes are able to meet the requirements for a PEM-FC. The compressed hydrogen is supplied to a hydrogen grid and can be used in small-scale decentralized CHP units. In this study it is assumed that the CHP units are based on low temperature PEM fuel cells. For the evaluation of alternative technologies the whole chain of centralized hydrogen production from biomass up to and including decentralized electricity production in PEM fuel cells is considered.Two models for the production of hydrogen from biomass and three models for the combined production of electricity and heat with PEM fuel cells are built using the computer program Cycle-Tempo. Two different levels of hydrogen purity are considered in this evaluation: 60% and 99.99% pure hydrogen. The purity of the hydrogen affects both the efficiencies of the hydrogen production as well as the PEM-FC systems. The electrical exergy efficiency of the PEM-FC system without additional heat production is calculated to be 27.66% in the case of 60% hydrogen and 29.06% in the case of 99.99% pure hydrogen. The electrical exergy efficiencies of the whole conversion chain appear to be 21.68% and 18.74%, respectively. The high losses during purification of the hydrogen gas result in a higher efficiency for the case with low purity hydrogen. The removal of the last impurities strongly increases the overall exergy losses of the conversion chain.     

Thermodynamic evaluation of hydrogen and electricity cogeneration coupled with very high temperature gas-cooled reactors

Hydrogen production using thermal energy, derived from nuclear reactor, can achieve large-scale hydrogen production and solve various energy problems. The concept of hydrogen and electricity cogeneration can realize the cascade and efficient utilization of high-temperature heat derive for very high temperature gas-cooled reactors (VHTRs). High-quality heat is used for the high-temperature processes of hydrogen production, and low-quality heat is used for the low-temperature processes of hydrogen production and power generation. In this study, two hydrogen and electricity cogeneration schemes (S1 and S2), based on the iodine-sulfur process, were proposed for a VHTR with the reactor outlet temperature of 950 °C. The thermodynamic analysis model was established for the hydrogen and electricity cogeneration. The energy and exergy analysis were conducted on two cogeneration systems. The energy analysis can reflect the overall performance of the systems, and the exergy analysis can reveal the weak parts of the systems. The analysis results show that the overall hydrogen and electricity efficiency of S1 is higher than that of S2, which are 43.6% and 39.2% at the hydrogen production rate of 100 mol/s, respectively. The steam generators is the components with the highest exergy loss coefficient, which are the key components for improving the system performance. This study presents a theoretical foundation for the subsequent optimization of hydrogen and electricity cogeneration coupled with VHTRs.     

Co-production of synthetic fuels and district heat from biomass residues,carbon dioxide and electricity: Performance and cost analysis

Large-scale systems suitable for the production of synthetic natural gas (SNG), methanol or gasoline (MTG) are examined using a self-consistent design, simulation and cost analysis framework. Three basic production routes are considered: (1) production from biomass via gasification; (2) from carbon dioxide and electricity via water electrolysis; (3) from biomass and electricity via hybrid process combining elements from routes (1) and (2). Process designs are developed based on technologies that are either commercially available or successfully demonstrated at precommercial scale. The prospective economics of future facilities coproducing fuels and district heat are evaluated from the perspective of a synthetic fuel producer. The levelised production costs range from 18–37 €/GJ for natural gas, 21–40 €/GJ for methanol and 23–48 €/GJ for gasoline, depending on the production route. For a given end-product, the lowest costs are associated with thermochemical plant configurations, followed by hybrid and electrochemical plants.     

A review on biomass‐based hydrogen production and potential applications

In this paper, a detailed review is presented to discuss biomass‐based hydrogen production systems and their applications. Some optimum hydrogen production and operating conditions are studied through a comprehensive sensitivity analysis on the hydrogen yield from steam biomass gasification. In addition, a hybrid system, which combines a biomass‐based hydrogen production system and a solid oxide fuel cell unit is considered for performance assessment. A comparative thermodynamic study also is undertaken to investigate various operational aspects through energy and exergy efficiencies. The results of this study show that there are various key parameters affecting the hydrogen production process and system performance. They also indicate that it is possible to increase the hydrogen yield from 70 to 107 g H₂ per kg of sawdust wood. By studying the energy and exergy efficiencies, the performance assessment shows the potential to produce hydrogen from steam biomass gasification. The study further reveals a strong potential of this system as it utilizes steam biomass gasification for hydrogen production. To evaluate the system performance, the efficiencies are calculated at particular pressures, temperatures, current densities, and fuel utilization factors. It is found that there is a strong potential in the gasification temperature range 1023–1423 K to increase energy efficiency with a hydrogen yield from 45 to 55% and the exergy efficiency with hydrogen yield from 22 to 32%, respectively, whereas the exergy efficiency of electricity production decreases from 56 to 49.4%. Hydrogen production by steam sawdust gasification appears to be an ultimate option for hydrogen production based on the parametric studies and performance assessments that were carried out through energy and exergy efficiencies. Finally, the system integration is an attractive option for better performance. Copyright © 2012 John Wiley & Sons, Ltd.     

Life cycle assessment of SNG from wood for heating, electricity, and transportation

The conversion of wood to synthetic natural gas (SNG) via gasification and catalytic methanation is a renewable close to commercialization technology that could substitute fossil fuels and alleviate global warming. In order to assure that it is beneficial from the environmental perspective, a cradle to grave life cycle assessment (LCA) of SNG from a first-of-its-kind polygeneration unit for heating, electricity generation, and transportation was conducted. These SNG systems were compared to fossil and conventional wood reference systems and environmental benefits from their substitution evaluated. Finally, we conduct sensitivity analysis for expected technological improvements and factors that could decrease environmental performance.It is shown that substituting fossil technologies with SNG systems is environmentally beneficial with regard to global warming and for selected technologies also with regard to aggregated environmental impacts. On the condition that process heat is used efficiently, technological improvements such as increased efficiency and denitrification could further increase this advantage. On the other hand, lower GHG emissions and aggregated impacts are partly compensated by other environmental effects, e.g. eutrophication, ecotoxicity, and respiratory disease caused by inorganics. Since more efficient alternatives exist for the generation of heat and electricity from wood, it is argued that SNG is best used for transportation. In the light of a growing demand for renewable transportation fuels and commercial scale technological development being only in its initial stage, the production of SNG from wood seems to be a promising technology for the near future.     

Innovative concept for gasification for hydrogen based on the heat integration between water gas shift unit and coal–water–slurry gasification unit

In order to achieve the energy cascade utilization and improve the energy utilization efficiency of coal–water–slurry (CWS) gasification for hydrogen system, the heat integration scheme (HIS) between the water gas shift unit and the gasification unit is put forward. The effects of temperature change of CWS and oxygen on the gasification performance are investigated. Both the HIS and the non-heat integration scheme (NHIS) are analyzed by using gasification performance, energy conversion efficiency and exergy efficiency. The results show that the specific coal consumption and the specific oxygen consumption decrease by 2.7% and 6.5%, respectively, as the feedstock is preheated up to the temperature of 150 °C. The energy conversion efficiency of HIS and NHIS are nearly the same. The exergy efficiency of HIS (62.66%) is better than that of NHIS (62.02%). Therefore, the HIS is better than the NHIS by heat integration between the WGS unit and the gasification unit.     

Energy and exergy analysis and optimization of biomass gasification process for hydrogen production (based on air,steam and air/steam gasifying agents)

Growing the consumption of fossil fuels and emerging global warming issue have driven the research interests toward renewable and environmentally friendly energy sources. Biomass gasification is identified as an efficient technology to produce sustainable hydrogen. In this work, energy and exergy analysis coupled with thermodynamic equilibrium model were implemented in biomass gasification process for production of hydrogen. In this regard, a detailed comparison of the performance of a downdraft gasifier was implemented using air, steam, and air/steam as the gasifying agents for horse manure, pinewood and sawdust as the biomass materials. The comparison results indicate that the steam gasification of pinewood generates a more desired product gas compositions with a much higher hydrogen exergy efficiency and low exergy values of unreacted carbon and irreversibility. Then the effects of the inherent operating factors were investigated and optimized applying a response surface methodology to maximize hydrogen exergy efficiency of the process. A hydrogen exergy efficiency of 44% was obtained when the product gas exergy efficiency reaches to the highest value (88.26%) and destruction and unreacted carbon efficiencies exhibit minimum values of 7.96% and 1.9%.     

Assessment of flexible energy vectors poly-generation based on coal and biomass/solid wastes co-gasification with carbon capture

This paper evaluates biomass and solid wastes co-gasification with coal for energy vectors poly-generation with carbon capture. The evaluated co-gasification cases were evaluated in term of key plant performance indicators for generation of totally or partially decarbonized energy vectors (power, hydrogen, substitute natural gas, liquid fuels by Fischer–Tropsch synthesis). The work streamlines one significant advantage of gasification process, namely the capability to process lower grade fuels on condition of high energy efficiency. Introduction in the evaluated IGCC-based schemes of carbon capture step (based on pre-combustion capture) significantly reduces CO₂ emissions, the carbon capture rate being higher than 90% for decarbonized energy vectors (power and hydrogen) and in the range of 47–60% for partially decarbonized energy vectors (SNG, liquid fuels). Various plant concepts were assessed (e.g. 420–425 MW net power with 0–200 MW_th flexible hydrogen output, 800 MW_th SNG, 700 MW_th liquid fuel, all of them with CCS). The paper evaluates fuel blending for optimizing gasification performance. A detailed techno-economic evaluation for hydrogen and power co-generation with CCS was also presented.     

Biomass gasification opportunities in a district heating system

This paper evaluates the economic effects and the potential for reduced CO₂ emissions when biomass gasification applications are introduced in a Swedish district heating (DH) system. The gasification applications included in the study deliver heat to the DH network while producing renewable electricity or biofuels. Gasification applications included are: external superheater for steam from waste incineration (waste boost, WB), gas engine CHP (BIGGE), combined cycle CHP (BIGCC) and production of synthetic natural gas (SNG) for use as transportation fuel. Six scenarios are used, employing two time perspectives – short-term and medium-term – and differing in economic input data, investment options and technical system. To evaluate the economic performance an optimisation model is used to identify the most profitable alternatives regarding investments and plant operation while meeting the DH demand. This study shows that introducing biomass gasification in the DH system will lead to economic benefits for the DH supplier as well as reduce global CO₂ emissions. Biomass gasification significantly increases the potential for production of high value products (electricity or SNG) in the DH system. However, which form of investment that is most profitable is shown to be highly dependent on the level of policy instruments for biofuels and renewable electricity. Biomass gasification applications can thus be interesting for DH suppliers in the future, and may be a vital measure to reach the 2020 targets for greenhouse gases and renewable energy, given continued technology development and long-term policy instruments.     

Small‐scale production of synthetic natural gas by allothermal biomass gasification

The gasification of biomass can be coupled to a downstream methanation process that produces synthetic natural gas (SNG). This enables the distribution of bioenergy in the existing natural gas grid. A process model is developed for the small‐scale production of SNG with the use of the software package Aspen Plus (Aspen Technology, Inc., Burlington, MA, USA). The gasification is based on an indirect gasifier with a thermal input of 500 kW. The gasification system consists of a fluidized bed reformer and a fluidized bed combustor that are interconnected via heat pipes. The subsequent methanation is modeled by a fluidized bed reactor. Different stages of process integration between the endothermic gasification and exothermic combustion and methanation are considered. With increasing process integration, the conversion efficiency from biomass to SNG increases. A conversion efficiency from biomass to SNG of 73.9% on a lower heating value basis is feasible with the best integrated system. The SNG produced in the simulation meets the quality requirements for injection into the natural gas grid. Copyright © 2012 John Wiley & Sons, Ltd.     

Conceptual design and analysis of a novel system based on ash agglomerating fluidized bed gasification for co-production of hydrogen and electricity

In this paper, a novel system with ash agglomerating fluidized bed gasification and CO₂ capture to produce hydrogen and electricity is firstly designed in Aspen Plus. The newly-proposed system is composed of eight subsystems, namely air separation unit, gasification unit, water gas shift unit, Rectisol unit, CO₂ compression unit, Claus unit, pressure swing adsorption unit, gas and steam turbine unit. The thermodynamic performance and hydrogen to coal ratio of the new proposed system are investigated. The results demonstrate that the hydrogen to coal ratio, energy efficiency, net electricity power and exergy efficiency of the overall system for Yangcheng anthracite are 0.096 kg/kg, 46.52%, 1.71 MW and 43.92%, respectively. Additionally, the exergy destruction ratio and exergy efficiency of each subsystem are researched. More importantly, the influences of the oxygen to coal ratio, steam to coal ratio and coal types on the hydrogen to coal ratio, energy efficiency and exergy efficiency are also studied.     

Energy and exergy analyses of the oxidation and gasification of carbon

Exergy losses in gasification and combustion of solid carbon are compared by conceptually dividing the processes into several subprocesses: instantaneous chemical reaction, heat transfer from reaction products to reactants (internal thermal energy exchange) and product mixing. Gasification is more efficient than combustion because exergy losses due to internal thermal energy exchange are reduced from 14–16 to 5–7% of expended exergy, while the chemical reactions are relatively efficient for both processes. The losses due to internal thermal energy exchange may be reduced by replacing air with oxygen, although this introduces additional process losses for separation of oxygen from air, or alternatively, preheating of air by heat exchange with product gas. For oxygen-blown gasification of fuels with high calorific value, such as solid carbon, it is advisable to moderate the temperature by introduction of steam. At optimum gasification temperatures in the ranges of 1100–1200 K (for atmospheric pressure) and 1200–1300 K (for 10 bar pressure), up to 75% of the chemical exergy contained in solid carbon can be preserved in the chemical exergy of carbon monoxide and hydrogen.