VTT TECHNICAL RESEARCH CENTRE OF FINLAND LTD Operational optimization and simulation of Power-to-Ammonia (P2A) process 18.05.17 NH3 Event 2017 Robert Weiss , Jouni Savolainen, Matti Tähtinen, Teemu Sihvonen, VTT Technical Research Centre of Finland Ltd., Finland Yasmina Bennani, Vincent Hans, Hans Vrijenhoef, Proton Ventures BV, The Netherlands
Contents § Introduction § Nitrogen fertilizer use in Europe § Small scale Power-to-Ammonia § Sizing and operation of a Power-to-Ammonia plant § Dynamic simulation: Virtual tests of plant dynamics § Robust optimization and market operations: Scheduling, profitability and CO 2 -emissions reduction in wind power intensive West Denmark. 18/05/17 2
Nitrogen fertilizer use in Europe Nitrogen fertiliser usage Installed wind capacity in Europe 2005 in Europe 2011 Source: Eurostat, 2016 Source: European Spatial Monitoring System, 2011 18/05/17 3
Nitrogen fertilizer use in Europe Nitrogen fertiliser usage Installed wind capacity in Europe 2005 in Europe 2011 Source: Eurostat, 2016 Source: European Spatial Monitoring System, 2011 18/05/17 4
Power to ammonia Small scale ammonia Feedstock : production makes it possible to • Electricity from renewable sources i.e. produce green decentralized wind turbines, PV ammonia which can be further • Air via N 2 /O 2 separation (PSA) used as: • Nitrogen carrier for fertilizers • Hydrogen carrier • Energy storage • Fuel 18/05/17 5 Source: http://www.protonventures.com
Wind-driven Small-scale Ammonia mill Nominal Full load Capacity Wind NH3 power capacity Wind power: - Intermittency - Forecasting errors: Uncertainty, depends on forecast horizon è Challenge for operational scheduling 18/05/17 6
Wind-driven Small-scale Ammonia mill Market Power PEM Overload Capacity 60% /30min Nominal Full load Capacity Part load 30-100% PEM Wind Flexible NH3 Electrolyzer power H 2 Ammonia H 2 capacity Buffer process Wind power: - Intermittency - Forecasting errors: Uncertainty, depends on forecast horizon è Challenge for operational scheduling 18/05/17 7
High-fidelty APROS simulator model for virtual test of process dynamics and control concepts Apros is a versatile high fidelty first principles dynamic simulator, including § thermal hydraulics networks, § automation & control, and § specialized dynamic models for § Power-to-gas electrolysis and § Haber-Bosch synthesis 18/05/17 www.apros.fi 8
Virtual test of power-to-ammonia dynamics: Primary Frequency Control operation in West Denmark (DK1) In this example test we used an optimal 5-day hourly operation plan for the power-to-ammonia plant: - Available wind power (Day-ahead Forecast) - Wholesales spot power purchase and sales (Day-ahead hourly) - Primary Frequency Control capacity sold (Day-ahead 4-hour blocks) - Running schedule for power-to-ammonia plant units (Day-ahead hourly) 5 d 18/05/17 www.apros.fi 9
Virtual test of power-to-ammonia dynamics: Primary Frequency Control operation in West Denmark (DK1) Schedule and TSO system frequency data (0.1-1s resolution) à the actual primary frequency control response of the PEM electrolyser units. à dynamic responses of all subsequent process units, and the plant power consumption. Power consumption including executed frequency control 18/05/17 www.apros.fi 10
Virtual test of power-to-ammonia dynamics: Primary Frequency Control operation in West Denmark (DK1) The operation mode performed well in the virtual tests. - Despite fast fluctuating power input, we achieved stable and good operating conditions (p,T) for NH 3 synthesis reactor - Some process valve controls had to be updated, especially for very large and fast transients. - Gas storages operation schedules: Daily initial and end-target storage levels important, some revision on sizes/max pressures Similar test results for following wind power production. Power consumption including executed frequency control H 2 balance and storage pressure NH 3 synthesis reactor 18/05/17 www.apros.fi 11
Small scale ammonia plant Operation optimization – example cases § Case 1: Plant inside the fence of a wind park § Subcase G50%: Restricted grid connection to 50% of wind park max capacity § Intra-day trade balances WP forecast error except for the final hour-ahead WP forecast § Robust optimization reserves optimal capacity to mitigate worst-case errors in final hour-ahead WP forecast § Assumed automatic load following within execution hour § Case 2: Plant in DSO grid, hourly Net Settlement with wind park § Subcase PFC : Plant is also able to sell Primary Frequency Control on day-ahead basis. § Load following not allowed. § Robust optimization reserves optimal day-ahead capacity to mitigate worst-case distortions for prolonged PFC response. § Case 3: P2NH 3 plant buying only market power and Certificates of Origin § Subcase PFC : like in case 2. 18/05/17 12
Example market area – West Denmark DK1 in 2016 We used • wind power production data, • power spot price data and • primary regulation price data of West Denmark, DK1 price and control area (Energinet.dk 2016; NordPool 2016). Grid fees in the cases ranged between 7.6 to 48.8 EUR/MWh. DK1 spot price • -54 to 105 €/MWh • average of 26.7 €/MWh 100% : WP prod. = consumption This area is well known for a high intensity of wind power, which during peak production times was up to 200% of the power consumption in the area during 2016. In 2015, 42% of the power used was wind power. 18/05/17 13
Case1: Plant inside the fence of a Wind Park Restricted grid connection to 50% of Wind Park max capacity 12.5 MW Wind park Hourly power production as in DK1 = same timing as DK1 market wind power Grid connection only 50% = 6.25 MW Grid connection capacity Without storage, 12.5% of the produced wind energy would be stranded 18/05/17 14
Case1: Plant inside the fence of a Wind Park Restricted grid connection to 50% of Wind Park max capacity 12.5 MW Wind park Hourly power production as in DK1 = same timing as DK1 market wind power Grid connection only 50% = 6.25 MW Grid connection capacity Without storage, 12.5% of the produced wind energy would be stranded à This was avoided! 4000 tNH 3 /year ammonia plant 5 MWe electrolysis (nominal) - 4 parallel PEM electrolysers - 60% overload capacity 5 hours intermediate H 2 buffer Haber-Bosch flexibility 30-100% 18/05/17 15
Wind power utilization and CO 2 emission reduction High Wind power utilization was reached for case 1 ”Inside Fence of Wind park” and case 2 ”Net Settlement ”. For case 3 ”pure market purchase”, only slighly higher WP than yearly average of grid was reached. PFC operation increased slightly market purchases, decreasing WP share. Case 3 increased the CO 2 -emissions of NH 3 production , since the non-WP share of grid market power purchases contain a high share of fossil based power, especially coal fired power. Wind power utilization includes here both • direct ”own” WP, and • indirect grid WP (hourly share of market purchases, via settlement calculation from DK1 official timeseries) 18/05/17 16
Wind power utilization and CO 2 emission reduction High Wind power utilization was reached for case 1 ”Inside Fence of Wind park” and case 2 ”Net Settlement ”. For case 3 ”pure market purchase”, only slighly higher WP than yearly average of grid was reached. PFC operation increased slightly market purchases, decreasing WP share. Case 3 increased the CO 2 -emissions of NH 3 production , since the non-WP share of grid market power purchases contain a high share of fossil based power, especially coal fired power. Wind power utilization includes here both • direct ”own” WP, and • indirect grid WP (hourly share of market purchases, via settlement calculation from DK1 official timeseries) 18/05/17 17
Wind power utilization and CO 2 emission reduction High Wind power utilization was reached for case 1 ”Inside Fence of Wind park” and case 2 ”Net Settlement ”. For case 3 ”pure market purchase”, only slighly higher WP than yearly average of grid was reached. PFC operation increased slightly market purchases, decreasing WP share. Case 3 increased the CO 2 -emissions of NH 3 production , since the non-WP share of grid market power purchases contain a high share of fossil based power, especially coal fired power. Wind power utilization includes here both • direct ”own” WP, and • indirect grid WP (hourly share of market purchases, via settlement calculation from DK1 official timeseries) 18/05/17 18
Wind power utilization and CO 2 emission reduction High Wind power utilization was reached for case 1 ”Inside Fence of Wind park” and case 2 ”Net Settlement ”. For case 3 ”pure market purchase”, only slighly higher WP than yearly average of grid was reached. PFC operation increased slightly market purchases, decreasing WP share. Case 3 increased the CO 2 -emissions of NH 3 production , since the non-WP share of grid market power purchases contain a high share of fossil based power, especially coal fired power. Wind power utilization includes here both • direct ”own” WP, and • indirect grid WP (hourly share of market purchases, via settlement calculation from DK1 official timeseries) 18/05/17 19
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