Process simulation and integration of IGCC systems for H2/syngas/electricity generation with control on CO2 emissions

IGCC is a pre-combustion technology that can be effectively used to produce both hydrogen and electricity while reducing the greenhouse gas (GHG) emissions. Two process models are developed in Aspen Plus^® software and are compared techno-economically. The conventional design of IGCC process is taken as case 1, whereas, case 2 represents the conceptual design of sequential integration of reforming model with the gasification unit to enhance the syngas yield. The case 2 utilizes the steam generated in the gasification process to sustain the methane reforming process which consequently enhances both the H₂ production capacity and cold gas efficiency. It has been analyzed from results that case 2 can enhance the process performance by 4.77% and economics in terms of cost of electricity by 5.9% compared to the conventional process. However, the utilization of natural gas in the case 2 is considered as a standalone fuel so the process performance of NGCC power plants has been also incorporated to ensure the realistic analysis. The results also showed that case 2 design offers 3.9% higher process performance than the cumulative (IGCC + NGCC) processes, respectively. Moreover, the CO₂ specific emissions and LCOE for the case 2 is also lower than the case.     

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 staged-gasification for hydrogen-rich syngas

Using Aspen Plus simulations, exergy analyses of hydrogen-rich syngas production via biomass staged-gasification are carried out for three configurations, namely, staged-gasification with pyrolysis gas combustion and char gasification (C-1), staged-gasification with pyrolysis gas reforming and char gasification (C-2), and staged-gasification with pyrolysis gas reforming and char combustion (C-3). The results show that, for the gasification and reforming processes, the exergy loss of pyrolysis gas with tar reforming is less than that of char gasification. As for the system, it is conducive to generating hydrogen by making full use of the hydrogen element (H) in biomass instead of the H in water. The benefits of C-1 are that it removes tar and produces higher yield and concentration of hydrogen. However, C-2 is capable of obtaining higher exergy efficiency and lower exergy loss per mole of H₂ production. C-3 theoretically has greater process performances, but it has disadvantages in tar conversion in practical applications. The appropriate gasification temperature (T_G) are in the range of 700–750 °C and the appropriate mass ratio of steam to biomass (S/B) are in the range of 0.6–0.8 for C-1 and C-3; the corresponding parameters for C-2 are in the ranges of 650–700 °C and 0.7–0.8, respectively.     

ZECOMIX: Performance of alternative lay-outs

ZECOMIX is a plant for hydrogen production and power generation using coal as a primary energy source and with nearly zero emissions. The global lay-out can be divided in 5 sectors: coal gasification, O₂ production, CO₂ capture, CO₂ sequestration, power generation. Coal is hydro gasified using a stream of hydrogen internally recycled. The syngas, mainly methane, is then reformed with steam and CaO in such a way to obtain a gaseous stream of hydrogen and steam separated from CaCO₃ which is solid. CaO is then regenerated inside a calciner which produce also a gaseous stream of CO₂ which has to be stored. The stream of hydrogen is burned with stoichiometric O₂ and the resulting steam is expanded in a steam power plant. After having focused our efforts on the coal gasification and CO₂ capture, we selected a layout for these sections and analysed the possibility to cogenerate hydrogen and power. The results confirmed that cogeneration is the most efficient solution and ZECOMIX seems to be an interesting option.     

Hydrogen and syngas production from sewage sludge via steam gasification

High temperature steam gasification is an attractive alternative technology which can allow one to obtain high percentage of hydrogen in the syngas from low-grade fuels. Gasification is considered a clean technology for energy conversion without environmental impact using biomass and solid wastes as feedstock. Sewage sludge is considered a renewable fuel because it is sustainable and has good potential for energy recovery. In this investigation, sewage sludge samples were gasified at various temperatures to determine the evolutionary behavior of syngas characteristics and other properties of the syngas produced. The syngas characteristics were evaluated in terms of syngas yield, hydrogen production, syngas chemical analysis, and efficiency of energy conversion. In addition to gasification experiments, pyrolysis experiments were conducted for evaluating the performance of gasification over pyrolysis. The increase in reactor temperature resulted in increased generation of hydrogen. Hydrogen yield at 1000 °C was found to be 0.076 g_gas g_sample⁻¹. Steam as the gasifying agent increased the hydrogen yield three times as compared to air gasification. Sewage sludge gasification results were compared with other samples, such as, paper, food wastes and plastics. The time duration for sewage sludge gasification was longer as compared to other samples. On the other hand sewage sludge yielded more hydrogen than that from paper and food wastes.     

Investigation of a novel & integrated simulation model for hydrogen production from lignocellulosic biomass

Process simulation and modeling works are very important to determine novel design and operation conditions. In this study; hydrogen production from synthesis gas obtained by gasification of lignocellulosic biomass is investigated. The main motivation of this work is to understand how biomass is converted to hydrogen rich synthesis gas and its environmentally friendly impact. Hydrogen market development in several energy production units such as fuel cells is another motivation to realize these kinds of activities. The initial results can help to contribute to the literature and widen our experience on utilization of the CO₂ neutral biomass sources and gasification technology which can develop the design of hydrogen production processes. The raw syngas is obtained via staged gasification of biomass, using bubbling fluidized bed technology with secondary agents; then it is cleaned, its hydrocarbon content is reformed, CO content is shifted (WGS) and finally H₂ content is separated by the PSA (Pressure Swing Adsorption) unit. According to the preliminary results of the ASPEN HYSYS conceptual process simulation model; the composition of hydrogen rich gas (0.62% H₂O, 38.83% H₂, 1.65% CO, 26.13% CO₂, 0.08% CH₄, and 32.69% N₂) has been determined. The first simulation results show that the hydrogen purity of the product gas after PSA unit is 99.999% approximately. The mass lower heating value (LHV_mass) of the product gas before PSA unit is expected to be about 4500 kJ/kg and the overall fuel processor efficiency has been calculated as ～93%.     

A novel integrated process for hydrogen production from biomass

A novel process, which integrated with biomass pyrolysis, gas–solid simultaneous gasification and catalytic reforming processes, was utilized to produce hydrogen. The effects of gasification temperature and reforming temperature on hydrogen yield and carbon conversion efficiency were investigated. The results showed that both higher gasification temperature and reforming temperature led to higher hydrogen yield and carbon conversion efficiency. Compared with the two-stage pyrolysis-catalytic reforming process, hydrogen yield and carbon conversion efficiency were greatly increased from 43.58 to 75.96 g H₂/kg biomass and 66.18%–82.20% in the integrated process.     

Hydrogen promotion by Co/SiO2@HZSM-5 core-shell catalyst for syngas from plastic waste gasification: The combination of functional materials

In the present work, a core-shell structured Co/SiO₂@HZSM-5 catalyst was prepared for hydrogen production from syngas of plastic waste gasification. The cobalt catalyst was coated with HZSM-5 shell through a hydrothermal process, and the Co/SiO₂@HZSM-5, with different loadings of HZSM-5 (e.g., 10–30 wt %) exhibited excellent activity and durability for dehydrogenation reactions. The amount of HZSM-5 was found to be an important factor for hydrogen production. Temperature-programmed reduction with H₂ and temperature-programmed desorption of ammonia was applied to determine the active site and the acidity of prepared catalyst, respectively. The prepared Co/SiO₂@HZSM-5 was tested through reforming of plastic gasification syngas and shown superior hydrogen production ability (∼90%) and stability (over 15 h). The effects of reduction-oxidation behavior on the catalytic performance were also discussed.     

Techno-economic feasibility of methanol synthesis using dual fuel system in a parallel process design configuration with control on green house gas emissions

Recently, the methanol production has received a lot of attraction in the process industries due to its wide applications in the synthesis of many commercial chemicals and fuels. Most of the coal to methanol processes suffers from higher water consumption, greenhouse gas (GHG) emissions and lower yields. The aim of this study is to develop a novel energy efficient and economic viable process that may not only increase the methanol production capacity but also offers the less energy requirements with improved process economics. In this study, coal gasification process is sequentially integrated in the parallel design configuration with the natural gas reforming technology to enhance the heating value of the resulting syngas for methanol production. To achieve this aim, two case studies have been developed and compared in terms of overall process performance and economics. Case 1 represents the conventional coal to methanol process, whereas, case 2 represents the conceptual design of integrating the gasification and reforming technologies for enhanced methanol production. The process efficiencies calculated for case 1 and case 2 is 63.2% and 70.0%, respectively. It has been seen from results that the methanol production energy for case 1 and case 2 is 0.69 kg/W and 0.76 kg/W, respectively. In terms of process economics, the methanol production cost for case 1 and case 2 has been estimated as 250 €/tonne and 234 €/tonne, respectively. The comparative analysis showed that the case 2 design not only offers higher process performance but also enhances the process feasibility compared to the conventional coal based processes.     

Techno-economic-environmental evaluation of a combined tri and dry reforming of methane for methanol synthesis with a high efficiency CO2 utilization

Production of methanol, as a green energy, from syngas is coming into focus. However, natural gas based methanol plants, which are used steam reforming of methane for syngas production, have a high CO₂ emission resulting in the global warming. In this study, a novel process for methanol synthesis is proposed to reduce CO₂ emission. In this regard, natural gas and flue gas are fed to a parallel-series system with tri and dry reforming of methane for syngas production with the optimized stoichiometric number. Then, the produced syngas is converted to methanol in a reactor. Finally, the produced methanol is purified by two distillation towers. The proposed method is compared to a referenced method in the view of technological, economic and environmental metrics. The techno-economic-environmental analysis of the processes reveals that not only the proposed method, as compared to the referenced one, increases CO₂ conversion from 20.93% to 99.22%, but also it is more economical and environmentally friendly. In addition, the global warming potential of the proposed method is almost 60% lower than that for the referenced method due to the lower CO₂ emission. Therefore, the proposed method can save above MUS$ 8 a year by CO₂ capture.     

Recent advances in biogas upgrading to value added products: A review

It is undeniable that oil and gas explorations are going on at a frantic pace due to excessive fossil fuel usage across the world. This has compelled us to explore isolated or even uninhabited places to meet the surging demand for oil and gas. There is no doubt that scientists and researchers worldwide are exploring more renewable energy sources to produce value-added products. In the last few years, biogas' usage as a reactant gas in the catalytic reforming process has emanated as an energy carrier to produce energy-efficient products, i.e., syngas and methanol. This review aimed to analyze the research works focusing on the biogas DR reactions and methanol production from biogas. The findings of some experimental studies have been presented in the form of graphs for important selective parameters as case studies. The overall impression from the review suggests that the performance of the reforming catalysts deteriorates regarding different operating conditions. Still, the improvement in syngas production has been reported by neglecting the effect of H₂S impurity. Furthermore, various parameters have been discussed paragraphically to evaluate the catalytic performance in biogas dry reforming reactions and a check on catalyst synthesis methods. After that, a few scattered studies have been discussed on methanol synthesis using biogas as a feedstock.     

A short overview on purification and conditioning of syngas produced by biomass gasification: Catalytic strategies,process intensification and new concepts

Application of the process intensification concept to biomass gasification is relatively recent, but is arousing growing interest by providing true opportunities for developing cost-effective high quality syngas, particularly for small to medium-scale installations, adapted to the economic context of most regions in the world. In this highly swarming context towards process intensification, this article provides an overview of the different strategies which are reported in the literature to perform syngas or H₂ purification and conditioning into the gasifier. A promising avenue towards process intensification consists in integrating several functionalities into suitable fluidized bed gasifiers, such as catalytic tar cracking/reforming, CO₂ elimination, H₂ separation and the elimination of particles and other contaminants. The development of new catalytic integrated gasification concepts is also proposed to achieve high conversion performances while pursuing significant process intensification. This strategy is illustrated by relevant examples such as the design of short contact time partial oxidation catalytic reactors, the implementation of specific reaction media such as supercritical water or molten metal, or the realisation of a close contact between solid catalysts and lignocellulosic biomass. Most of these different technologies are not mature yet and research effort has to be performed for optimizing each of these approaches, calling for a multidisciplinary and multi-scale approach integrating catalysis, chemistry, reaction and process engineering. The design of new advanced gasification reactor concept still has to be pursued in order to achieve the challenging one-step production of a high quality syngas from biomass gasification. The implementation of such innovative biomass gasification breakthrough concepts could be one of the most promising ways of process intensification resulting in a significant cut down of the production costs of synthesis gas and H₂ derived from biomass.     

Hydrogen production from biomass and plastic mixtures by pyrolysis-gasification

The addition of plastics to the steam pyrolysis/gasification of wood sawdust with and without a Ni/Al₂O₃ catalyst was investigated in order to increase the production of hydrogen in the gaseous stream. To study the influence of the biomass/plastic ratio in the initial feedstock, 5, 10 and 20 wt.% of polypropylene was introduced with the wood in the pyrolysis reactor. To investigate the effect of plastic type, a blend of 80 wt.% of biomass and 20 wt.% of either polypropylene, high density polyethylene, polystyrene or a mixture of real world plastics was fed into the reactor. The results showed that a higher gas yield (56.9 wt.%) and a higher hydrogen concentration and production (36.1 vol.% and 10.98 mmol H₂ g⁻¹ sample, respectively) were obtained in the gaseous fraction when 20 wt.% of polypropylene was mixed with the biomass. This significant improvement in gas and hydrogen yield was attributed to synergetic effects between intermediate species generated via co-pyrolysis. The Ni/Al₂O₃ catalyst dramatically improved the gas yield as well as the hydrogen concentration and production due to the enhancement of water gas shift and steam reforming reactions. Very low amounts of coke (less than 1 wt.% in all cases) were formed on the catalyst during reaction, with the deposited carbonaceous material being of the filamentous type. The Ni/Al₂O₃ catalyst was shown to be effective for hydrogen production in the co-pyrolysis/gasification process of wood sawdust and plastics.     

Thermodynamic evaluation of hydrogen production from methane

Exergetic and energetic analysis has been utilized to estimate the effect of process design and conditions on the hydrogen purity and yield, exergetic efficiencies and CO₂ avoided. Methane was chosen as a model compound for evaluating single stage separation. Simple steam reforming was considered as the base – case system. The other chemical processes that were considered were steam reforming with CO₂ capture with and without chemical looping of a reactive carbon dioxide removal agent, and steam gasification with both the Boudouard reaction catalyst and the reactive carbon dioxide removal agent with and without the solids regeneration. The information presented clearly demonstrates the differences in efficiencies between the various chemical looping processes for hydrogen generation. The incremental changes in efficiencies as a function of process parameters such as temperature, steam amount, chemical type and amount were estimated. Energy and exergy losses associated with generation of syngas, separation of hydrogen from CO_x as well as exergetic loss associated with emissions are presented. The optimal conditions for each process by minimizing these losses are presented. The majority of the exergy destruction occurs due to the high irreversibility of chemical reactions. The results of this investigation demonstrate the utility of exergy analysis. The paper provides a procedure for the comparison of various technologies for the production of hydrogen from carbon based materials based on First and Second Law Analysis. In addition, two figures of merit, namely the comparative advantage factor and the sustainable advantage factor have been proposed to compare the various hydrogen production methods using carbonaceous fuels.     

Biomass gasification for sustainable energy production: A review

Gasification process is considered as one of the best routes of energy recovery from biomass by producing syngas mostly including H₂, CO, and CH₄. Biomass as the main renewable energy resources has great advantages regarding its diversity, availability, and sustainability for supplying energy needs in heat, electricity production, biofuel production for transportation, etc. Various gasifiers based on the gasifying process and agents have been examined. This paper reviewed the theory of biomass gasification by comparing and analyzing different gasification models-designs and configurations, also different operational conditions. It aimed to bring a holistic approach for hydrogen rich syngas production based on the present technologies, techno-economic analysis, and industrial/commercialization pathways. The biomass gasification technologies need to be improved for hydrogen production regarding the global environmental and economic issues. The review provided better insights into the enhancement of syngas production from biomass.     

Investigation of a methanol processing system comprising of a steam reformer and two preferential oxidation reactors for fuel cells

Methanol steam reforming is able to produce hydrogen-rich syngas onsite for fuel cells and avoids the problems of hydrogen storage. Nevertheless, CO in the reformate needs to be further removed to ppm level before it can be fed into proton exchange membrane fuel cells. In this study, a methanol processing system consisting of a methanol reformer and two-stage preferential oxidation reactors is developed. The hydrogen production performance and scalability of the reformer are experimentally investigated under various operating conditions. The methanol reformer system shows stable methanol conversion rate and linearly increased H₂ flow rate as the number of repeating unit increases. Methanol conversion rate of 96.8% with CO concentration of 1.78% are achieved in the scaled-up system. CO cleanup ability of the two-stage preferential oxidation reactors is experimentally investigated based on the reformate compositions by varying the operating temperature and O₂ to CO ratios. The results demonstrate that the developed CO cleanup train can decrease the CO concentration from 1.6% to below 10 ppm, which meets the requirement of the fuel cell. Finally, stability of the integrated methanol processing system is tested for 180 h operation.     

Technoeconomic analysis of a low CO2 emission dimethyl ether (DME) plant based on gasification of torrefied biomass

Two models of a dimethyl ether (DME) fuel production plant were designed and analyzed in DNA and Aspen Plus. The plants produce DME by either recycle (RC) or once through (OT) catalytic conversion of a syngas generated by gasification of torrefied woody biomass. Torrefication is a mild pyrolysis process that takes place at 200–300 °C. Torrefied biomass has properties similar to coal, which enables the use of commercially available coal gasification processing equipment. The DME plants are designed with focus on lowering the total CO₂ emissions from the plants; this includes e.g. a recycle of a CO₂ rich stream to a CO₂ capture plant, which is used in the conditioning of the syngas.     

Hydrogen-rich syngas production and carbon dioxide formation using aqueous urea solution in biogas steam reforming by thermodynamic analysis

Biogas is a renewable biofuel that contains a lot of CH₄ and CO₂. Biogas can be used to produce heat and electric power while reducing CH₄, one of greenhouse gas emissions. As a result, it has been getting increasing academic attention. There are some application ways of biogas; biogas can produce hydrogen to feed a fuel cell by reforming process. Urea is also a hydrogen carrier and could produce hydrogen by steam reforming. This study then employes steam reforming of biogas and compares hydrogen-rich syngas production and carbon dioxide with various methane concentrations using steam and aqueous urea solution (AUS) by Thermodynamic analysis. The results show that the utilization of AUS as a replacement for steam enriches the production of H₂ and CO and has a slight CO₂ rise compared with pure biogas steam reforming at a temperature higher than 800 °C. However, CO₂ formation is less than the initial CO₂ in biogas. At the reaction temperature of 700 °C, carbon formation does not occur in the reforming process for steam/biogas ratios higher than 2. These conditions led to the highest H₂, CO production, and reforming efficiency (about 125%). The results can be used as operation data for systems that combine biogas reforming and applied to solid oxide fuel cell (SOFC), which usually operates between 700 °C to 900 °C to generate electric power in the future.     

Comparing prospective hydrogen pathways with conventional fuels and grid electricity in India through well-to-tank assessment

The present study uses Greenhouse Gases, Regulated Emissions, and Energy Use in Technologies Model (GREET), to compare hydrogen generated via multiple pathways (Natural gas, methanol reforming; coal, petcoke, biomass gasification etc) with the conventional fuels like diesel and compressed natural gas and grid electricity under Indian context through a comprehensive well to tank assessment based on net CO₂ equivalent emission and energy consumption. Limited availability of customized studies comparing hydrogen production and supply with other energy options in India distinguishes the present work as it provides a fresh insight into potential pathways for hydrogen production while assessing feedstock availability and raw water consumption. The study reveals that biomass gasification and solar electrolysis are among the least GHG emitting pathways to fill one unit of energy equivalent in the tank. Hydrogen produced through natural gas reforming is 70% less emission intensive and 38% more energy efficient than Indian grid electricity.     

An overview of solar decarbonization processes,reacting oxide materials,and thermochemical reactors for hydrogen and syngas production

Solar decarbonization processes are related to the different thermochemical conversion pathways of hydrocarbon feedstocks for solar fuels production using concentrated solar energy as the external source of high-temperature process heat. The main investigated routes aim to convert gaseous and solid feedstocks (methane, coal, biomass …) into hydrogen and syngas via solar cracking/pyrolysis, reforming/gasification, and two-step chemical looping processes using metal oxides as oxygen carriers, further associated with thermochemical H₂O/CO₂ splitting cycles. They can also be combined with metallurgical processes for production of energy-intensive metals via solar carbothermal reduction of metal oxides. Syngas can be further converted to liquid fuels while the produced metals can be used as energy storage media or commodities. Overall, such solar-driven processes allow for improvements of conversion yields, elimination of fossil fuel or partial feedstock combustion as heat source and associated CO₂ emissions, and storage of intermittent solar energy in storable and dispatchable chemical fuels, thereby outperforming the conventional processes. The different solar thermochemical pathways for hydrogen and syngas production from gaseous and solid carbonaceous feedstocks are presented, along with their possible combination with chemical looping or metallurgical processes. The considered routes encompass the cracking/pyrolysis (producing solid carbon and hydrogen) and the reforming/gasification (producing syngas). They are further extended to chemical looping processes involving redox materials as well as metallurgical processes when metal production is targeted. This review provides a broad overview of the solar decarbonization pathways based on solid or gaseous hydrocarbons for their conversion into clean hydrogen, syngas or metals. The involved metal oxides and oxygen carrier materials as well as the solar reactors developed to operate each decarbonization route are further described.