Synergistic Integration of Energy Systems and Closed-Loop Manufacturing Systems ASME Energy Sustainability Conference Present ntatio ion: n: PowerEne rEnergy gy2018-7611 June e 27, 2018 Dr. Benjamin J. Cross, PE Stephanie Howe Michael Zimmer 1
PORTSFUTURE OHIO UNIVERSITY VOINOVICH SCHOOL OF LEADERSHIP AND PUBLIC AFFAIRS DOE EDUCATIONAL ASSISTANCE GRANT PUBLIC OUTREACH AND APPLIED-ENVIRONMENTAL TASKS FOR THE FORMER PORTSMOUTH GASEOUS DIFFUSION PLANT (PORTS) IN PIKETON, OHIO AND SURROUNDING COUNTIES 2
Outline • Premise for Integration • Integrated Energy System (IES) • Closed-Loop Manufacturing (CLM) • Process Heat Applications & Usage • PORTS IES-CLM Complex Concept • IES-CLM Potential Benefits • IES-CLM Challenges • Summary/Conclusions 3
Premise Premise for Integration for Integration Systems/processes optimized to work together addresses the Nexus of Energy, Water, Climate, Food, and Waste • The “whole” is worth more than some of the “parts” – Synergy obtained from a “systems of systems” approach • “Smart Systems” can create “Smart Solutions” • “Value” as a driver—not absolute “cost” – Value Propositions: High Efficiency (i.e., Thermal, Economic) High Reliability and Resiliency Sustainability Minimal water usage Low Emissions/Waste Minimization Acceptable/Low Cost 4
Inte Integrate grated Energy Syste d Energy System • Technical definition: Two or more energy resources are utilized as inputs to two or more physically coupled subsystems to produce one or more energy commodities as outputs • Simpler definition: Multiple energy resources combined together to produce one or more energy related products • IES is not a technology, but integrated approach to applying technologies, “ systems of systems” • Co-locating, combining, interconnecting and/or networking of energy producers and energy users 5
IES IES by Diff y Different erent Name Names • Cogeneration (Traditional among technical people) – Usually thought of as a single energy resource producing two energy commodities • Combined Heat and Power (CHP) – Natural Gas/Coal/Oil/Biomass to produce steam (process heat) for a chemical process and additionally generate electricity • Hybrid Energy Systems • Combined Energy Systems • Polygeneration 6
China & Polygeneration Coal chemical recycling economy demonstration park in Wuzhong City in Ningxia Providence 7
Closed Closed-Loop Loop Man Manuf ufactur acturing ing (Industr (In dustrial ial Symb Symbiosi iosis) s) Typical industrial process used today 8
Process Heat Applications Hydrogen Production by Water Splitting, Coal Gasification Hydrogen Production by Steam Methane Reforming Ethanol Concentration Water Purifications Utilize process heat at every temperature level 9
Process H Process Heat eat Usa Usage High Temp Anaerobic Digestion Food Waste Biomass Drying Processing Water Fish Farm & Treatment Cosmetics Specialty Chemicals Hatcheries PORTS Pharmaceuticals Solvents (~1200 acres) High Temperature, Algae Hazard, Security, & Grow/Green Plastics Polymers/ Farms Investment , Houses Resins (Electricity, Hydrogen, Adhesives Ammonia Production, Cleaning Refinery, Metal Extraction Methanol &Treatment ) Agents Facility District Bulk Chemicals Pulp & Paper Heating Heating Water Processing Purification Low Temp Enzymatic/Fermentation 10
Closed Closed-Lo Loop op Coo Cooling ling Wat ater er Refinery Anaerobic CCGT Digesters Fish Hatchery Water Treatment Green Houses Algae Grow Ponds Houses
IES-CLM IES CLM Complex Complex Conce Concept pt Power Grid Renewables (Solar/Wind) Electricity Natural Gas (NG) Generation High Temperature Biomass (e.g., wood chips, Process Heat Ag energy grasses/crops) Heat (e.g., Steam) Sources Municipal Solid Waste (MSW) Hydrogen Natural Gas (NG) Heat Users Production Nuclear Fuel (NF) ( Future ) Hydrogen (H 2 ) Carbon Dioxide (CO 2 ) H 2 Users (e.g., Fuel Cells ) CO 2 Users Oil ( e.g.Enhanced Oil Methanol Hydro- Ammonia Vegetable Recovery) Carbon Production genation Coal Production Oils AIR Monoxide Refinery Refrigeration MSW & Liquifer Solid or Methanol Ammonia semi-solid Tires CH 3 OH NH 3 fats Liquid & Hydrocarbons Biomass (Margarine, Solid CO 2 Shortening) & Alcohols Baking and Transportation fuels, Fertilizers, metals Fuels, Cleaning solvents, food processing heating fuels, bulk & extraction & treating, antifreeze, beverages, food specialty chemicals, plastics, cleaning polymers, processing, refrig- pharmaceuticals, agents, industrial plastics, resins, eration, pharma- industrial solvents, refrigeration, food solvents, ceuticals, polymers, resins & processing, emissions adhesives, waste cosmetics plastics control, waste water water treatment treatment 12
Initial Phase of IES Initial Phase of IES-CLM CLM AIR AIR AIR NG Heat NG Recovery Exhaust Gas Steam (CO 2 , H 2 O, Generator NO X ) 8 HRSG Exhaust Gas NG Fluidized Recovery Duct Burner Syngas(CO) 4 Bed Steam H 2 O MSW Boiler Biomass Gas Turbine Electricity Generator Steam 1 Exhaust Gas (CO 2 , H 2 O, 10 NO X ) Solid Residue Electricity Steam Deaerator & Turbine Economizer Generator Feedwater (Pre-heater) Heater Condensate Return Condenser 5 8 9 Steam Demineralized 2 Methane Water H 2 NG Reformer Water Treatment 3 Make-up Water (Un-fired) CO 2 CO 6 7 Coolant 4 (Syngas) 13
Additional Ad ditional Phases of IES Phases of IES-CLM CLM H 2 2 2 CO H 2 H 2 H 2 H 2 Vegetable (Syngas) Oils AIR 4 Haber- Catalytic Oil Methanol (N 2 ) Hydro- Bosch Synthesis Coal genation Process Refinery CO 2 Solid or semi- MSW (Hydrodealkylation, Ammonia 15 18 11 solid fats 21 hydrodesulfurization, Methanol (NH 3 ) (Margarine, Tires hydrocracking, CH 3 OH Shortening) hydrogenating, etc.) Urea Biomass Synthesis & 5 Formox Food Granulation Process Industry CO 2 H 2 O O 2 Extracted Hydrocarbons Urea( carbamide ) 16 chemicals Methanal Baked 19 (Fertilizer) & Alcohols 22 (Formaldehyde) Goods (NH 2 ) 2 CO 11 CH 2 O & Processed 14 CO 2 Foods Eurotecnica Melamine Numerous process 20 NH 3 Synthesis 13 Char industrial & 17 Polymers consumer Melamine Steam Resins 12 Sulfur products C 3 N 6 H 6 1 1 3 3 CO 2 14
IE IES-CLM P CLM Pote otential ntial Benef Benefits its • Effective resource management (Cost Savings) – Higher overall efficiency – Recycling of water and materials, including CO 2 – Better utilization of capital equipment and lower operating expenses Shared resources (e.g. infrastructure, facilities, personnel) Shared processes (e.g. common/support systems) • Use of local domestic and renewable resources • Reduced waste and emissions • Promotes sustainability on an industrial scale • Industry collaboration and co-location • Transformation of brownfield sites 15
Challenges • Multiple organizations working together (Planning) Must integrate people before you can integrate systems • Large Capital Investment ($B’s) • Security (investment protection) Potential terrorist target • Requires unique sites (Megasites) Near energy and other natural resources Intensive industrial and support infrastructure • Flexibility and resiliency Dependent and independent operations • Phased development and incorporation of new technology 16
Summary • IES-CLM is not a new concept or technology but an integrated approach for applying technologies “Systems of Systems” approach focused on comprehensive synergistic integration • IES-CLM provides opportunity to optimize efficiency and effective resource management Minimize cost and impact on the environment • IES-CLM addresses the nexus of energy, water, climate, food, and waste on an industrial scale 17
For more information on the project, visit www.portsfuture.com The PORTSfuture project is funded by a grant from the U.S. Department of Energy Office of Environmental Management Portsmouth/Paducah Project Office 18
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