Four different configurations of a 5 kW class shell-and-tube methane steam reformer with a low-temperature heat source

The methane steam reforming reaction is an extremely high endothermic reaction that needs a high temperature heat source. Various fuel cell hybrid systems have been developed to improve the thermal efficiency of the entire system. This paper presents a low temperature steam reformer for those hybrid systems to maximize the utilization of energy from a low temperature waste heat source. In this study, the steam reformer has a shell and tube configuration that is divided into the following zones: the inlet heat exchanging zone, the reforming zone and the exit heat exchanging zone. Four different configurations for methane steam reformers are developed to examine the effect of heat transfer on the methane conversion performance of the low temperature steam reformer. The experimental results show that the overall heat transfer area is a critical parameter in achieving a high methane conversion rate. When the heat transfer area increases about 30%, the results showed elevated dry mole fractions of hydrogen about 3% with about 30 °C rise of reformer outlet temperature.     

Design and evaluation of hybrid propulsion ship powered by fuel cell and bottoming cycle

Fuel cells are a promising power source in the electric propulsion systems for zero-emission vessels. The electric efficiency of fuel cells can be increased to 55% practically, but significant amounts of remaining energy from the electrochemical reaction are wasted as heat. This article proposes a hybrid propulsion system for ships that utilizes both the electric energy and thermal energy generated by fuel cells. The electric power capacity of fuel cells and the steam generation capacity of recovered heat from fuel cell systems are calculated, and then the propulsion power of the hybrid system is simulated by MATLAB Simulink. The overall energy efficiency of the proposed ship propulsion system is compared with that of conventional systems by comparing fuel consumption rate. Simulation results indicate that the proposed hybrid propulsion system can increase energy efficiency by 22.5% by additional utilization of the recovered heat from fuel cells.     

Electrical and electrical–thermal power plants with molten carbonate fuel cell/gas turbine‐integrated systems

In this article the calculation tool further developed and implemented in Matlab language by the authors was used to determine some optimal operating conditions in electrical and thermal or electrical terms for two different types of hybrid systems: molten carbonate fuel cells (MCFC)/gas turbine with their heat recovery system and the hybrid systems operating in these optimal conditions were analyzed. In the heat recovery system, in both cases, a part of the thermal energy of these gases is used to produce the steam necessary for the MCFC system. The remaining thermal energy is used, in one case, for the production of steam at various levels of pressure and temperature, which feeds a steam bottom plant to produce additional electric energy; in the other case, the same thermal energy is used to produce steam for cogenerative use. The heat recovery system was suitably designed according to the circumstances and the performances and the specific CO₂ emissions of the hybrid systems were evaluated. Copyright © 2010 John Wiley & Sons, Ltd.     

Mobile hydraulic power supply: Liquid piston Stirling engine pump

Conventional mobile hydraulic power supplies involve numerous kinematic connections and are limited by the efficiency, noise, and emissions of internal combustion engines. The Stirling cycle possesses numerous benefits such as the ability to operate from any heat source, quiet operation, and high theoretical efficiency. The Stirling engine has seen limited success due to poor heat transfer in the working chambers, difficulty sealing low-molecular weight gases at high pressure, and non-ideal piston displacement profiles. As a solution to these limitations, a liquid piston Stirling engine pump is proposed. The liquid pistons conform to irregular volumes, allowing increased heat transfer through geometry features on the interior of the working chambers. Creating near-isothermal operation eliminates the costly external heat exchangers and increases the engine efficiency through decreasing the engine dead space. The liquid pistons provide a positive gas seal and thermal transport to the working chambers. Controlling the flow of the liquid pistons with valves enables matching the ideal Stirling cycle and creates a direct hydraulic power supply. Using liquid hydrogen as a fuel source allows cooling the compression side of the engine before expanded the fuel into a gas and combusting it to heat the expansion side of the engine. Cooling the compression side not only increases the engine power, but also significantly increases the potential thermal efficiency of the engine. A high efficiency Stirling engine makes energy regeneration through reversing the Stirling cycle practical. When used for regeneration, the captured energy can be stored in thermal batteries, such as a molten salt. The liquid piston Stirling engine pump requires further research in numerous areas such as understanding the behavior of the liquid pistons, modeling and optimization of a full engine pump, and careful selection of materials for the extreme operating temperatures. Addressing these obtainable research quandaries will enable a transformative Stirling engine pump with the potential to excel in numerous applications.     

Latest concepts for combustion and waste heat recovery systems being considered for hydrogen engines

A more sustainable transportation calls for the use of alternative and renewable fuels, a further increase of the fuel energy conversion efficiency of internal combustion engines as well as the reduction of the thermal engine energy supply by recovering the braking energy. The paper presents two concepts being developed to improve the fuel conversion efficiency of internal combustion engines for transport applications. The first concept works on the combustion evolution to increase the amount of fuel energy transformed in piston work within the cylinder. The second concept works on the waste exhaust and coolant energies to be recovered through a power turbine downstream of the turbocharger turbine on the exhaust line and a steam turbine feed with the steam produced by a boiler/super heater made of the coolant passages and a heat exchanger on the exhaust line. The concepts work with hydrogen (and in this case a water injector is also necessary) as well as lower alkanes (methane, propane, butane). Preliminary simulations show improvement of top fuel conversion efficiencies to above 50% in the high power density operation. The waste heat recovery system also permits faster warm-up during cold start driving cycles.     

Molten carbonate fuel cell (MCFC)-based hybrid propulsion systems for a liquefied hydrogen tanker

This study proposes a molten carbonate fuel cell (MCFC)-based hybrid propulsion system for a liquefied hydrogen tanker. This system consists of a molten carbonate fuel cell and a bottoming cycle. Gas turbine and steam turbine systems are considered for recovering heat from fuel cell exhaust gases. The MCFC generates a considerable propulsion power, and the turbomachinery generates the remainder of the power. The hybrid systems are evaluated regarding system efficiency, economic feasibility, and exhaust emissions. The MCFC with a gas turbine has higher system efficiency than that with a steam turbine. The air compressor consumes substantial power and should be mechanically connected to the gas turbine. Although fuel cell-based systems are less economical than other propulsion systems, they may satisfy the environmental regulations. When the ship is at berth, the MCFC systems can be utilized as distributed generation that is connected to the onshore-power grid.     

固体氧化物燃料电池与燃气轮机混合发电的发展及甲烷蒸汽重整的研究

燃料电池与燃气轮机混合发电系统有着很高的能量利用效率,是能量转换的重要研究方向。而固体氧化物燃料电池的蒸汽重整技术为该联合提供了重要的技术支持。本文设计了固体氧化物燃料电池的结构,并进行甲烷蒸汽重整的模拟计算,计算结果显示燃料电池排气温度达到1380K左右时,有很高的能量利用价值。     

Enhancing efficiency of hydrocarbons to synthesis gas conversion in a counterflow moving bed filtration combustion reactor

An improvement is considered for the partial oxidation conversion of hydrocarbon gases to synthesis gas in a continuous non-premixed filtration combustion reactor with inert solid granular material flowing countercurrently to the gas flow. The reactor is supplemented with an additional heat exchanger, wherein the second reactant gas is preheated prior to supply to the middle part of the reactor. The composition of the gaseous products self-consistent with the temperature of combustion are assessed using approximation of established thermodynamic equilibrium in the products. The parametric domain for major control parameters, namely oxygen-to-fuel supply ratio, granular solid flowrate, and steam supply rate providing highly efficient conversion is determined. Calculations for the POX conversion of methane and a model biogas composition (50% methane, 40% carbon dioxide, 10% nitrogen) with air and steam are provided as examples. The calculations show that the process gives a possibility to substantially improve energy efficiency and provides a flexibility to control hydrogen yield through steam supply. The process provides a high chemical efficiency of conversion even with air used as an oxidant for conversion of low-caloric gases.     

Charge,mass and heat transfer interactions in solid oxide fuel cells operated with different fuel gases—A sensitivity analysis

The interaction between charge, heat and mass transfer occurring in SOFCs is investigated applying a finite-volume-based SOFC model. The strong interactions are the consequence of the high degree of integration of different processes (chemical/electrochemical reactions, diffusion, heat and mass transfer) within SOFCs. The understanding of these interactions is a key for the future development and application of SOFCs. The investigation was conducted by means of a sensitivity analysis for two different fuel gases, where one gas features a considerable amount of methane inducing steam reforming reactions as additional disturbance factor in the energy and mass balance system of SOFCs. In order to isolate the impact of the varied model parameters and the according changes in the interactions of charge, mass and heat transfer from side effects, the sensitivity analysis was conducted at constant fuel utilization. It was found that the impact of different fuel gases on the operational conditions of SOFCs dominates geometrical and material-induced phenomena. The power output was most affected by the fuel, followed by the values for the activation polarization activation energy that reflects the employed electrode catalysts activity.     

Exergy based performance analysis of a solid oxide fuel cell and steam injected gas turbine hybrid power system

This paper presents exergy analysis of a hybrid solid oxide fuel cell and gas turbine (SOFC/GT) system in comparison with retrofitted system with steam injection. It is proposed to use hot gas turbine exhaust gases heat in a heat recovery steam generator to produce steam and inject it into gas turbine. Based on a steady-state model of the processes, exergy flow rates are calculated for all components and a detailed exergy analysis is performed. The components with the highest proportion of irreversibility in the hybrid systems are identified and compared. It is shown that steam injection decreases the wasted exergy from the system exhaust and boosts the exergetic efficiency by 12.11%. Also, 17.87% and 12.31% increase in exergy output and the thermal efficiency, respectively, is demonstrated. A parametric study is also performed for different values of compression pressure ratio, current density and pinch point temperature difference.     

Syngas production from oxidative methane reforming and CO cleaning with water gas shift reaction

Fuel cell based heat and power cogeneration is considered to be well qualified for a distributed energy system for residential and small business applications. A fuel processing unit including an oxidative steam methane reformer, a high temperature shift reactor and a low temperature shift reactor is under development in South China University of Technology. Performance of the unit is experimentally investigated in a bench-scale experimental setup. Processor performance under typical operating conditions is tested. The influence of reaction temperature, methane space velocity in the oxidative steam methane reformer, and air to carbon molar ratio on unit performances is experimentally studied. It is found that under the typical operating conditions, the total energy efficiency reaches 88.3%. The efficiency can further be improved by utilizing the sensible heat of the reformate gas. The current study has been focused on the chemical performances such as methane conversion of the reformer and CO concentration in the synthesis gas downstream water gas shift reactors. Heat integration of the unit will be further implemented in future to improve energy efficiency.     

Theory and performance analysis of a new heat engine for concentrating solar power

The objectives of this paper are to introduce a new heat engine and evaluate its performance. The new heat engine uses a gas, such as air, nitrogen, or argon, as the working fluid and extracts thermal energy from a heat source as the energy input. The new heat engine may find extensive applications in renewable energy industries, such as concentrating solar power (CSP). Additionally, the heat engine may be employed to recover energy from exhaust streams of internal combustion engines, gas turbine engines, and various industrial processes. It may also work as a thermal‐to‐mechanical conversion system in a nuclear power plant and function as an external combustion engine in which the heat source is the combustion gas from an external combustion chamber. The heat engine is to mimic the performance of an air‐standard Otto cycle. This is achieved by drastically increasing the time duration of heat acquisition from the heat source in conjunction with the timing of the heat acquisition and a large heat transfer surface area. Performance simulations show that the new heat engine can potentially attain a thermal efficiency above 50% and a power output above 100 kW under open‐cycle operation. Additionally, the heat engine could significantly reduce CSP costs and operate in open cycles, effectively removing the difficulties of dry cooling requirement for CSP applications. Copyright © 2014 John Wiley & Sons, Ltd.     

优化生产运行，实现乙烯装置节能降耗

近年来中国石化广州分公司乙烯的能耗水平逐年下降,综合能耗从2003年的725．04kg标油/t下降至2005年的682．48kg标油/t。主要措施为：①通过回收火炬气、应用低压甲烷烧嘴等措施对燃料气系统进行优化。同时优化了炼油区和化工区的燃料气配置,减少了燃料气损失;②通过改由自备热电站输送蒸汽、减少蒸汽放空、透平与电泵切换操作等措施对蒸汽系统进行了平衡和优化,减少了蒸汽损耗;③优化了裂解原料,提高了乙烯收率。提出了进～步节能降耗的设想。     

Exergy analysis of the woody biomass Stirling engine and PEM-FC combined system with exhaust heat reforming

The woody biomass Stirling engine (WB-SEG) is an external combustion engine that outputs high-temperature exhaust gases. It is necessary to improve the exergy efficiency of WB-SEG from the viewpoint of energy cascade utilization. So, a combined system that uses the exhaust heat of WB-SEG for the steam reforming of city gas and that supplies the produced reformed gas to a proton exchange membrane fuel cell (PEM-FC) is proposed. The energy flow and the exergy flow were analyzed for each WB-SEG, PEM-FC, and WB-SEG/PEM-FC combined system. Exhaust heat recovery to preheat fuel and combustion air was investigated in each system. As a result, (a) improvement of the heat exchange performance of the woody biomass combustion gas and engine is observed, (b) reduction in difference in the reaction temperature of each unit, and (c) removal of rapid temperature change of reformed gas are required in order to reduce exergy loss of the system. The exergy efficiency of the WB-SEG/PEM-FC combined system is superior to EM-FC.     

An advanced zero emission power cycle with integrated low temperature thermal energy

An innovative zero emission hybrid cycle named HICES (hybrid and improved CES cycle) is presented in this paper. It can utilize fossil fuel and low quality thermal energy such as waste heat from industrial processes and solar thermal energy for highly efficient electric power generation. In the HICES cycle, natural gas is internally combusted with pure oxygen. External low quality thermal energy is used to produce saturated steam between 70 and 250 °C as part of the working fluid. The thermodynamic characteristics at design conditions of the HICES cycle are analyzed using the advanced process simulator Aspen Plus. The influences of some key parameters are investigated. The results demonstrate that the thermodynamic performances of the HICES cycle are quite promising. For example, when the external heat produced saturated steam is at 70 °C, the net fuel-to-electricity efficiency is 54.18% even when taking into account both the energy penalties to produce pure oxygen and to liquefy the captured CO₂. The incremental low temperature heat to electric efficiency is as high as 14.08% at the same time. When the external heat produced saturated steam is at 250 °C, the net fuel-to-electricity efficiency reaches 62.66%. The incremental low temperature heat to electric efficiency achieves 48.92%.     

Theoretical analysis and optimum integration strategy of the PEM fuel cell and internal combustion engine hybrid system for vehicle applications

The hybrid system comprised by a proton exchange membrane (PEM) fuel cell and internal combustion engine shows many advantages for vehicle applications. The hybrid system can recover the un‐reacted hydrogen from fuel cell, utilize heat in the combustion product from cylinder, or combine the advantages of both. Based on thermodynamics and electrochemistry, an indirect integration system of the PEM fuel cell and Otto cycle is established for vehicle applications. The irreversibilities such as the entropy production and overpotentials in the fuel cell, the finite‐rate heat transfer between the air in the Otto cycle and combustion chamber wall, the irreversible compression, expansion, and regeneration processes in the Otto cycle are considered. The excellence of the PEM fuel cell compared with internal combustion engine is shown in terms of energy conversion efficiency. When the vehicle is speeding or launching suddenly, not only the flow rate of natural gas into the hybrid system should be increased but also a specific coupling mode between two powertrain systems should be found. Copyright © 2015 John Wiley & Sons, Ltd.     

Hydrogen production from methane and solar energy – Process evaluations and comparison studies

Three conventional and novel hydrogen and liquid fuel production schemes, i.e. steam methane reforming (SMR), solar SMR, and hybrid solar-redox processes are investigated in the current study. H₂ (and liquid fuel) productivity, energy conversion efficiency, and associated CO₂ emissions are evaluated based on a consistent set of process conditions and assumptions. The conventional SMR is estimated to be 68.7% efficient (HHV) with 90% CO₂ capture. Integration of solar energy with methane in solar SMR and hybrid solar-redox processes is estimated to result in up to 85% reduction in life-cycle CO₂ emission for hydrogen production as well as 99–122% methane to fuel conversion efficiency. Compared to the reforming-based schemes, the hybrid solar-redox process offers flexibility and 6.5–8% higher equivalent efficiency for liquid fuel and hydrogen co-production. While a number of operational parameters such as solar absorption efficiency, steam to methane ratio, operating pressure, and steam conversion can affect the process performances, solar energy integrated methane conversion processes have the potential to be efficient and environmentally friendly for hydrogen (and liquid fuel) production.     

Research and development of a low-BTU gas-driven engine for waste gasification and power generation

Combustion characteristics of low-BTU gases (about 1000 kcal/N m³) were experimentally investigated in order to develop engine generators for waste gasification and power generation systems. Two simulated low-BTU gases, obtained from one-step high temperature gasification (hydrogen rich) and two-step pyrolysis/reforming gasification (methane rich), as well as natural gas, were tested in a small-scale spark ignition engine. Compared to the natural gas driven engine, the hydrogen rich low-BTU gas driven engine showed similar thermal efficiency but with significantly lower NO_x and hydrocarbon emissions and wider equivalence ratio range for stable engine operation. On the other hand, the methane rich low-BTU gas engine showed narrower equivalence ratio range for stable operation. The test results show engine performance more depends on combustion characteristics than on the heating value of the fuel gas. For better engine performance, hydrogen rich fuel gas is desirable.     

Modeling and optimization of a typical fuel cell–heat engine hybrid system and its parametric design criteria

A theoretical modeling approach is presented, which describes the behavior of a typical fuel cell–heat engine hybrid system in steady-state operating condition based on an existing solid oxide fuel cell model, to provide useful fundamental design characteristics as well as potential critical problems. The different sources of irreversible losses, such as the electrochemical reaction, electric resistances, finite-rate heat transfer between the fuel cell and the heat engine, and heat-leak from the fuel cell to the environment are specified and investigated. Energy and entropy analyses are used to indicate the multi-irreversible losses and to assess the work potentials of the hybrid system. Expressions for the power output and efficiency of the hybrid system are derived and the performance characteristics of the system are presented and discussed in detail. The effects of the design parameters and operating conditions on the system performance are studied numerically. It is found that there exist certain optimum criteria for some important parameters. The results obtained here may provide a theoretical basis for both the optimal design and operation of real fuel cell–heat engine hybrid systems. This new approach can be easily extended to other fuel cell hybrid systems to develop irreversible models suitable for the investigation and optimization of similar energy conversion settings and electrochemistry systems.     

Thermodynamic analysis of a new combined cooling, heat and power system driven by solid oxide fuel cell based on ammonia-water mixture

Although a solid oxide fuel cell combined with a gas turbine (SOFC-GT) has good performance, the temperature of exhaust from gas turbine is still relatively high. In order to recover the waste heat of exhaust from the SOFC-GT to enhance energy conversion efficiency as well as to reduce the emissions of greenhouse gases and pollutants, in this study a new combined cooling, heat and power (CCHP) system driven by the SOFC is proposed to perform the trigeneration by using ammonia-water mixture to recover the waste heat of exhaust from the SOFC-GT. The CCHP system, whose main fuel is methane, can generate electricity, cooling effect and heat effect simultaneously. The overall system performance has been evaluated by mathematical models and thermodynamic laws. A parametric analysis is also conducted to examine the effects of some key thermodynamic parameters on the system performance. Results indicate that the overall energy conversion efficiency exceeds 80% under the given conditions, and it is also found that the increasing the fuel flow rate can improve overall energy conversion efficiency, even though both the SOFC efficiency and electricity efficiency decrease. Moreover, with an increased compressor pressure ratio, the SOFC efficiency, electricity efficiency and overall energy conversion efficiency all increase. Ammonia concentration and pressure entering ammonia-water turbine can also affect the CCHP system performance.