System Evaluation and Life-Cycle Cost Analysis of a Commercial-Scale High-Temperature Electrolysis Hydrogen Production Plant

Results of a system evaluation and lifecycle cost analysis are presented for a commercial-scale high-temperature electrolysis (HTE) central hydrogen production plant. The plant design relies on grid electricity to power the electrolysis process and system components, and industrial natural gas to provide process heat. The HYSYS process analysis software was used to evaluate the reference central plant design capable of producing 50,000 kg/day of hydrogen. The HYSYS software performs mass and energy balances across all components to allow optimization of the design using a detailed process flow sheet and realistic operating conditions specified by the analyst. The lifecycle cost analysis was performed using the H2A analysis methodology developed by the Department of Energy (DOE) Hydrogen Program. This methodology utilizes Microsoft Excel spreadsheet analysis tools that require detailed plant performance information (obtained from HYSYS), along with financial and cost information to calculate lifecycle costs. The results of the lifecycle analyses indicate that for a 10% internal rate of return, a large central commercial-scale hydrogen production plant can produce 50,000 kg/day of hydrogen at an average cost of $2.68/kg. When the cost of carbon sequestration is taken into account, the average cost of hydrogen production increases by$0.40/kg to $3.08/kg

System Evaluations and Life-Cycle Cost Analyses for High-Temperature Electrolysis Hydrogen Production Facilities

This report presents results of system evaluations and lifecycle cost analyses performed for several different commercial-scale high-temperature electrolysis (HTE) hydrogen production concepts. The concepts presented in this report rely on grid electricity and non-nuclear high-temperature process heat sources for the required energy inputs. The HYSYS process analysis software was used to evaluate both central plant designs for large-scale hydrogen production (50,000 kg/day or larger) and forecourt plant designs for distributed production and delivery at about 1,500 kg/day. The HYSYS software inherently ensures mass and energy balances across all components and it includes thermodynamic data for all chemical species. The optimized designs described in this report are based on analyses of process flow diagrams that included realistic representations of fluid conditions and component efficiencies and operating parameters for each of the HTE hydrogen production configurations analyzed. As with previous HTE system analyses performed at the INL, a custom electrolyzer model was incorporated into the overall process flow sheet. This electrolyzer model allows for the determination of the average Nernst potential, cell operating voltage, gas outlet temperatures, and electrolyzer efficiency for any specified inlet steam, hydrogen, and sweep-gas flow rates, current density, cell active area, and external heat loss or gain. The lifecycle cost analyses were performed using the H2A analysis methodology developed by the Department of Energy (DOE) Hydrogen Program. This methodology utilizes spreadsheet analysis tools that require detailed plant performance information (obtained from HYSYS), along with financial and cost information to calculate lifecycle costs. There are standard default sets of assumptions that the methodology uses to ensure consistency when comparing the cost of different production or plant design options. However, these assumptions may also be varied within the spreadsheets when better information is available or to allow the performance of sensitivity studies. The selected reference plant design for this study was a 1500 kg/day forecourt hydrogen production plant operating in the thermal-neutral mode. The plant utilized industrial natural gas-fired heaters to provide process heat, and grid electricity to supply power to the electrolyzer modules and system components. Modifications to the reference design included replacing the gas-fired heaters with electric resistance heaters, changing the operating mode of the electrolyzer (to operate below the thermal-neutral voltage), and considering a larger 50,000 kg/day central hydrogen production plant design. Total H2A-calculated hydrogen production costs for the reference 1,500 kg/day forecourt hydrogen production plant were $3.42/kg. The all-electric plant design using electric resistance heaters for process heat, and the reference design operating below the thermal-neutral voltage had calculated lifecycle hydrogen productions costs of$3.55/kg and $5.29/kg, respectively. Because of its larger size and associated economies of scale, the 50,000 kg/day central hydrogen production plant was able to produce hydrogen at a cost of only$2.89/kg

The Concept and Analytical Investigation of CO2 and Steam Co-Electrolysis for Resource Utilization in Space Exploration

CO2 acquisition and utilization technologies will have a vital role in designing sustainable and affordable life support and in situ fuel production architectures for human and robotic exploration of Moon and Mars. For long-term human exploration to be practical, reliable technologies have to be implemented to capture the metabolic CO2 from the cabin air and chemically reduce it to recover oxygen. Technologies that enable the in situ capture and conversion of atmospheric CO2 to fuel are essential for a viable human mission to Mars. This paper describes the concept and mathematical analysis of a closed-loop life support system based on combined electrolysis of CO2 and steam (co-electrolysis). Products of the coelectrolysis process include oxygen and syngas (CO and H2) that are suitable for life support and synthetic fuel production, respectively. The model was developed based on the performance of a co-electrolysis system developed at Idaho National Laboratory (INL). Individual and combined process models of the co-electrolysis and Sabatier, Bosch, Boudouard, and hydrogenation reactions are discussed and their performance analyses in terms of oxygen production and CO2 utilization are presented

Sensitivity Studies of Advanced Reactors Coupled to High Temperature Electrolysis (HTE) Hydrogen Production Processes

High Temperature Electrolysis (HTE), when coupled to an advanced nuclear reactor capable of operating at reactor outlet temperatures of 800 °C to 950 °C, has the potential to efficiently produce the large quantities of hydrogen needed to meet future energy and transportation needs. To evaluate the potential benefits of nuclear-driven hydrogen production, the UniSim process analysis software was used to evaluate different reactor concepts coupled to a reference HTE process design concept. The reference HTE concept included an Intermediate Heat Exchanger and intermediate helium loop to separate the reactor primary system from the HTE process loops and additional heat exchangers to transfer reactor heat from the intermediate loop to the HTE process loops. The two process loops consisted of the water/steam loop feeding the cathode side of a HTE electrolysis stack, and the steam or air sweep loop used to remove oxygen from the anode side. The UniSim model of the process loops included pumps to circulate the working fluids and heat exchangers to recover heat from the oxygen and hydrogen product streams to improve the overall hydrogen production efficiencies. The reference HTE process loop model was coupled to separate UniSim models developed for three different advanced reactor concepts (a high-temperature helium cooled reactor concept and two different supercritical CO2 reactor concepts). Sensitivity studies were then performed to evaluate the affect of reactor outlet temperature on the power cycle efficiency and overall hydrogen production efficiency for each of the reactor power cycles. The results of these sensitivity studies showed that overall power cycle and hydrogen production efficiencies increased with reactor outlet temperature, but the power cycle producing the highest efficiencies varied depending on the temperature range considered

Engineering Process Model for High-Temperature Electrolysis System Performance Evaluation

In order to evaluate the potential hydrogen production performance of large-scale High-Temperature Electrolysis (HTE) operations, we have developed an engineering process model at INL using the commercial systems-analysis code HYSYS. Using this code, a detailed process flowsheet has been defined that includes all of the components that would be present in an actual plant such as pumps, compressors, heat exchangers, turbines, and the electrolyzer. Since the electrolyzer is not a standard HYSYS component, a custom one-dimensional electrolyzer model was developed for incorporation into the overall HYSYS process flowsheet. This electrolyzer model allows for the determination of the operating voltage, gas outlet temperatures, and electrolyzer efficiency for any specified inlet gas flow rates, current density, cell active area, and external heat loss or gain. The one-dimensional electrolyzer model was validated by comparison with results obtained from a fully 3-D computational fluid dynamics model developed using FLUENT. This report provides details on the one-dimensional electrolyzer model, the HYSYS process model for a 300 MW HTE plant, and some representative results of parametric studies performed using the HYSYS process model

Demonstration and System Analysis of High Temperature Steam Electrolysis for Large-Scale Hydrogen Production Using SOFCs

At the Idaho National Engineering Laboratory, an integrated laboratory scale (ILS), 15 kW high-temperature electrolysis (HTE) facility has been developed under the U.S. Department of Energy Nuclear Hydrogen Initiative. Initial operation of this facility resulted in over 400 hours of operation with an average hydrogen production rate of approximately 0.9 Nm3/hr. The integrated laboratory scale facility is designed to address larger-scale issues such as thermal management (feed-stock heating, high-temperature gas handling), multiple-stack hot-zone design, multiple-stack electrical configurations, and other “integral” issues. Additionally, a reference process model of a commercial-scale high-temperature electrolysis plant for hydrogen production has been developed. The reference plant design is driven by a 600 megawatt thermal high-temperature helium-cooled reactor coupled to a direct Brayton power cycle. The electrolysis unit used to produce hydrogen consists of 4.01×106 cells with a per-cell active area of 225 cm2. A nominal cell area-specific resistance, ASR, value of 0.4 Ohm•cm2 with a current density of 0.25 A/cm2 was used, and isothermal boundary conditions were assumed. The overall system thermal-to-hydrogen production efficiency (based on the low heating value of the produced hydrogen) is 47.1% at a hydrogen production rate of 2.36 kg/s with the high-temperature helium-cooled reactor concept. This paper documents the initial operation of the ILS, with experimental details about heat-up, initial stack performance, as well as long-term operation and stack degradation. The paper will also present the optimized design for the reference nuclear-driven HTE hydrogen production plant which may be compared with other hydrogen production methods and power cycles to evaluate relative performance characteristics and plant economics

Mathematical Analysis of a Novel Approach to Maximize Waste Recovery in a Life Support System

NASA has been evaluating closed-loop atmosphere revitalization architectures carbon dioxide, CO2, reduction technologies. The CO2 and steam, H2O, co-electrolysis process is another option that NASA has investigated. Utilizing recent advances in the fuel cell technology sector, the Idaho National Laboratory, INL, has developed a CO2 and H2O co-electrolysis process to produce oxygen and syngas (carbon monoxide, CO and hydrogen, H2 mixture) for terrestrial (energy production) application. The technology is a combined process that involves steam electrolysis, CO2 electrolysis, and the reverse water gas shift (RWGS) reaction. Two process models were developed to evaluate novel approaches for waster recovery in a life support system. The first is a model INL co-electrolysis process combined with a methanol production process. The second is the INL co-electrolysis process combined with a pressure swing adsorption (PSA) process. For both processes, the overall power increases as the syngas ratio, H2/CO, increases because more water is needed to produce more hydrogen at a set CO2 incoming flow rate. The power for the methanol cases is less than the PSA because heat is available from the methanol reactor to preheat the water and carbon dioxide entering the co-electrolysis process

Integrating Nuclear Energy to Oilfield Operations -- Two Case Studies

Fossil fuel resources that require large energy inputs for extraction, such as the Canadian oil sands and the Green River oil shale resource in the western USA, could benefit from the use of nuclear power instead of power generated by natural gas combustion. This paper discusses the technical and economic aspects of integrating nuclear energy with oil sands operations and the development of oil shale resources. A high temperature gas reactor (HTGR) that produces heat in the form of high pressure steam (no electricity production) was selected as the nuclear power source for both fossil fuel resources. Both cases were based on 50,000 bbl/day output. The oil sands case was a steam-assisted, gravity-drainage (SAGD) operation located in the Canadian oil sands belt. The oil shale development was an in-situ oil shale retorting operation located in western Colorado, USA. The technical feasibility of the integrating nuclear power was assessed. The economic feasibility of each case was evaluated using a discounted cash flow, rate of return analysis. Integrating an HTGR to both the SAGD oil sands operation and the oil shale development was found to be technically feasible for both cases. In the oil sands case, integrating an HTGR eliminated natural gas combustion and associated CO2 emissions, although there were still some emissions associated with imported electrical power. In the in situ oil shale case, integrating an HTGR reduced CO2 emissions by 88% and increased natural gas production by 100%. Economic viabilities of both nuclear integrated cases were poorer than the non-nuclear-integrated cases when CO2 emissions were not taxed. However, taxing the CO2 emissions had a significant effect on the economics of the non-nuclear base cases, bringing them in line with the economics of the nuclear-integrated cases. As we move toward limiting CO2 emissions, integrating non-CO2-emitting energy sources to the development of energy-intense fossil fuel resources is becoming increasingly important. This paper attempts to reduce the barriers that have traditionally separated fossil fuel development and application of nuclear power and to promote serious discussion of ideas about hybrid energy systems

Mummified precocial bird wings in mid-Cretaceous Burmese amber

Our knowledge of Cretaceous plumage is limited by the fossil record itself: compression fossils surrounding skeletons lack the finest morphological details and seldom preserve visible traces of colour, while discoveries in amber have been disassociated from their source animals. Here we report the osteology, plumage and pterylosis of two exceptionally preserved theropod wings from Burmese amber, with vestiges of soft tissues. The extremely small size and osteological development of the wings, combined with their digit proportions, strongly suggests that the remains represent precocial hatchlings of enantiornithine birds. These specimens demonstrate that the plumage types associated with modern birds were present within single individuals of Enantiornithes by the Cenomanian (99 million years ago), providing insights into plumage arrangement and microstructure alongside immature skeletal remains. This finding brings new detail to our understanding of infrequently preserved juveniles, including the first concrete examples of follicles, feather tracts and apteria in Cretaceous avialans

The Beginning and Evolution of the Universe

We review the current standard model for the evolution of the Universe from an early inflationary epoch to the complex hierarchy of structure seen today. We summarize and provide key references for the following topics: observations of the expanding Universe; the hot early Universe and nucleosynthesis; theory and observations of the cosmic microwave background; Big Bang cosmology; inflation; dark matter and dark energy; theory of structure formation; the cold dark matter model; galaxy formation; cosmological simulations; observations of galaxies, clusters, and quasars; statistical measures of large-scale structure; and measurement of cosmological parameters. We conclude with discussion of some open questions in cosmology. This review is designed to provide a graduate student or other new worker in the field an introduction to the cosmological literature.Comment: 69 pages. Invited review article for Publications of the Astronomical Society of the Pacific. Supplementary references, tables, and more concise PDF file at http://www.physics.drexel.edu/univers