1. GDR Europeen “Energetica and Safety of Hydrogen”
2007 annual meeting
ICARE-CNRS, Orleans
Integrated system for hydrogen production and use in distributed generation
Leonardo Tognotti
Università di Pisa
Consorzio Pisa Ricerche

2. Outline
The “FISR” project “Integrated system for hydrogen production……….”
Objectives and approach
Tasks and Partners
Some examples
International Flame Research Foundation
Status and organisation
Research Programmes on H2–related topics

3. Hydrogen Vector

4. La road map dell’UE 2040 2030 2020 2010 Idrogeno 2050 Fonti fossili
Trasporto su strada e produzione on site alla
stazione di servizio (reforming ed elettrolisi) H 2
prodotto da fossili con sequestro CO
Ampie reti di idrogenodotti
Aumento della decarbonizzazione della produzione H2
Rinnovabili, fossili con sequestro CO2 e nuovo nucleare
Celle a combustibile diventano una tecnologia di largo impiego per trasporto, generazione di potenza e microgenerazione
2040
Idrogeno
2050
Fonti fossili
2000
Motori a combustione interna ad idrogeno

5. Why Hydrogen from coal …
… three good reasons
Coal can be decarbonized and up-graded through hydrogen;
Coal is an available and reliable source to start the technological and political path towards Hydrogen economy
Coal is the most available and has the lowest geopolitical risk of all the fossil fuels

6. Conversion- Sources Zero emissions Utilization Oil Generazione
Reforming
Reforming
Generazione
Distributed
potenza
energy
Coal
Gassification
Fossil
Natural Gas
Reforming
Reforming
generation
distribuita
Idrogenodotti
Carbone
Gassificazione
Gassificazione
Residenziale
Residential CO 2
Nuclear
Thermochemical
Processi
HYDROGEN
IDROGENO
tProcesses
termochimici
Industry
Industria 2
Eolico, PV
Wind, PV
Electrolysis
Elettrolisi
Richiede accumulo e
distribuzione H
Trasportation
Trasporto
Renewable
Solar
Solare
Thermochemical
Processi
termochimici
Processes CO 2
Biomass
Biomasse
Other
Gassification
Gassificazione
CO sequestration
Confinamento CO 2 2

7. The concept: integrating the H2 production
MWe
to sequestration
electricity
Schematization of the integrated process for hydrogen production

8. Challenges
Achievement of cost-effective technologies for hydrogen production, storage, distribution and use
Achievement of commercial utilisation of hydrogen in distributed applications, e.g. transportation and residences
Reduction of urban pollution (better air quality) from stationary combustion sources and automotive sources
Reduction of CO2 emissions by sequestration and reuse

10. Project Objectives
identification and development of H2 production processes from solid fuels, integrated with centralised power plants:
H2 production at acceptable costs and satisfactory purity for distributed generation applications
reduction of environmental impact of H2 production processes
development of technologies for the utilisation of produced H2 in cogenerative systems for microgeneration (microturbines, stirling engines):
high efficiencies and towards “zero emission” solutions
assessment of the economic and environmental benefits in comparison to traditional methods, in order to select the most suitable process depending on the fuel and the H2 utilisation system

11. FISR Fondo Integrativo Speciale per la Ricerca -
Programma strategico: Nuovi Sistemi di Produzione e Gestione dell’Energia
Progetto obiettivo: Vettore Idrogeno
Titolo del progetto: Sistemi Integrati di Produzione di Idrogeno e sua Utilizzazione nella Generazione Distribuita
Sigla
Partecipante
CPR / UNIPI
Consorzio Pisa Ricerche / Università di Pisa – PISA
ENEL
Enel Produzione Spa – ROMA
CNR/IRC
Consiglio Nazionale delle Ricerche / Istituto Ricerche sulla Combustione – NAPOLI
UNINA
Università di Napoli “Federico II” - NAPOLI
UNIGE
Università di Genova – GENOVA
CRS4
Centro di Ricerca, Sviluppo e Studi Superiori in Sardegna - CAGLIARI
RIELLO
Riello Spa - Legnago (VR)
ENI
Eni- San Donato Milanese (MI)

12. Integrated Systems for Hydrogen Production and Use in Distributed Generation
Approach
Innovative components, technologies and systems are developed in order to minimise the environmental impact and to make competitive the production of hydrogen.
Advanced methodologies are used for technical, economical and environmental assessment (LCA)
The integration of the hydrogen production/separation process with a centralised power plant operating with the same fuel is crucial for the technological and economic feasibility, supplying energy, steam, heat, whereas the residue char can be used as fuel in the combustion plant

13. Integrated Systems for Hydrogen Production and Use in Distributed Generation
Approach
Most activities are experimental tests on small and pilot plants using specific instrumental and analytical devices.
This work is coupled with fundamental modelling for a detailed simulation of the processes. It allows dynamic problems and process scaling-up to be evaluated and discussed to solve problems arisen during the experimental phase
Finally, the different scenarios are modelled for technical-economical- environmental feasibility

14. The utilisation of the future potential requires:
Towards zero emissions: integrated gasification combined cycle State of knowledge
Gasification is an old technology ↔ knowledge base is low : IGCC-CCS power plant today is a combination of available gasification and gas cleaning technologies, the efficiency potential is not used.
Future CCS-PP require higher efficiencies
Research demand
The utilisation of the future potential requires:
Concepts with integrated gas cleaning (future concepts like membranes and fuel cells)
High temperature gas cleaning and separation
Modelling of gasification and gas cooling
Materials for high temperatures and reducing conditions
KEY for future IGCC CCS power plants:
Knowledge of coal behaviour including mineral matter and trace components at highest temp./ pressures and reducing conditions

15. Gasification options
direct gasification (heat provided by partial oxidation)
indirect gasification (heat provided by heat vector)
steam gasification
gasification with CO2 sorbent

16. Method for process development
Process definition
Process boundary
Potentiality
Integration
Definition of functional units
Unit modelling
Range of operating conditions
Unit connections
Definition of process parameters
Target parameters
Operating variables
Monitoring parameters (operating constraints)
Process optimization
Sensitivity analysis
Comparison of different solutions:
Change of functional units
Change of inter-connections
TOOLS:
Thermodynamic Database
Aspen Plus ™ /similar codes
Dedicated softwares / Developed models

17. Process definition Centralized Power Plant Emission Treatment Units
PYROLYSIS/
GASIFICATION
UNIT
GAS CLEAN UP AND
HEAT RECOVERY
UNITS
WATER GAS SHIFT
REACTION UNIT
HYDROGEN SEPARATION
heat, steam, energy, emissions
Solid fuel
(coal or biomass)
Fuel Storage
Fuel Pre-treatment
Hydrogen Production Plant
CO2 Sequestration Plant
20,000 kg/hr of HS Coal
Hydrogen Distribution
Hydrogen Utilisation
Scenario for distributed generation:
2500 kg/hr of H2 required for 80 MW

18. Example n.1. Pyrolytic Cracking

19. Reasearch Needs
Pyrolysis/gasification units (CPR/UNIPI, UNINA/IRC, UNIGE, ENEL)
Solid fuel characterisation (coals, biomasses)
Reactor development and optimisation
Modelling homogeneous/heterogeneous reactions
Technological problems
Residue characterisation and reuse
Tar cracking unit : lab-scale tar cracking unit (CPR/UNIPI)
Water gas shift (UNIGE)
Separation unit (ENI, ENEL, CPR/UNIPI, CRS4- (modelling))

20. Schema dell’Impianto ENEL di Bastardo (PG)
Attività 1.1.1
(ENEL)
Sviluppo di reattore pilota e ottimizzazione del processo
Attività pregressi:
Giornata di Studio
Sistemi innovativi di produzione di idrogeno da energie rinnovabili

21. Line 2: Separation options
traditional water gas shift reaction + pressure swing adsorption (ENI)
membrane reactor (simultaneous water gas shift reaction and hydrogen separation using a membrane) (UNIGE)
membrane separation: experimental characterisation and modelling (CPR/UNIPI)
Modelling activities (CRS4)

22. Natural gas infrastructure for promoting diffusion of H2
Opportunities in Hydrogen Distribution
Costs abatement of H2 introduction using the existing network for NG transportation and distribution
Hydrogen
Natural Gas
Technological issues
Safety
Durability and reliability of pipelines
Performances of end uses
Separation Hydrogen/methane
Pure H2 Area
Natural gas infrastructure for promoting diffusion of H2

23. Introduzione
Obiettivi
Metodologia
Risultati
Discussione
Conclusioni

24. From standards

26. Hydrogen mixtures Introduzione Obiettivi Metodologia Risultati
Discussione
Conclusioni

27. Hydrogen Utilization options (mixture from 50 to 100%)
Diffusive burners for H2-rich mixtures (H2/CH4/N2)
Advanced combustors (HiTAC/flameless/MILD, porous)
Catalytic combustors
Hybrid combustors (-flameless post-porous)
Microturbines
Two main objectives
Upgrading of conventional burners and combustion chambers for H2-enriched fuels (syngas, up to 50%)
Design and development of new devices for pure H2 combustion (switching from air to oxygen)

28. H2 combustion: new research issues
Advanced numerical simulation on high performance H/W systems and development of models of turbulent combustion
Chemical kinetics (detailed vs. reduced)
Experimental on lab and pilot scale, with advanced diagnostics

29. Objectives and methodology
Investigation of 2 burners placed at ENEL Ricerca laboratories of Livorno:
Burner n°1: industrial recuperative flameless combustion burner (FLOX®)
Burner n°2: burner for heat/power micro-cogeneration CHP (SOLO®)
Both burners are designed to operate in flameless combustion regime when fed with NG, but how do they behave when H2 is added to the fuel?
Gain insight on operating parameters affecting flameless combustion;
Gain insight on numerical models for flameless combustion.
Method
CFD aided experiments

30. Method CFD simulation of flameless combustion is not easy:
model validation
CFD
measurements understanding
EXPERIMENTS
planning experimental campaign
burner design improvements
predictions
measurements
CFD simulation of flameless combustion is not easy:
Combustion models:
Turbulence-chemistry interaction
Da 1  “mixed is burnt” approaches are unsuited
Turbulence models
Kinetics
model validation is needed!

31. Burner n°1 FLOX® 13 kW self-recuperative burner
applications: furnaces for steel annealing processes, glass making
Inconel© shield and water jacket in the experimental rig coaxially to the burner
Fuel: CH4 and CH4/H2
Measurements:
T (flue gases, radiant tube and Inconel© shield)
Flue gas composition
Flow rates

32. CFD model of Burner n°1: computational domain and grid
Modelling approach
radiant tube
Computational domain
3 windows allow recirculation of exhaust gases into rection region
120° angular sector
1 fluid domain and 2 solid domains (flame and radiant tubes)
Computational mesh
ICEM by Ansys Inc
~400,000 cells
hybrid mesh (hexahedras + tetraedras)
flame tube
recirculation window
flame tube
radiant tube
outlet
fuel inlet
air inlet

33. CFD modelling of an industrial burner operating in flameless mode
30th Topic Oriented Technical Meeeting (TOTeM30)
October 25-26, 2007
CFD modelling of an industrial burner operating in flameless mode
Modelling approach
Physical model:
CFX 5.7 by Ansys Inc.
Turbulence model: standard k-ε
Radiation model: Discrete Transfer Radiation Model, P1
Spectral model: Gray, WSGG
Combustion model:
Eddy Dissipation/Finite Rate model for CH4 oxidation
Finite Rate model for NO formation
Kinetics
CH4/H2 Oxidation: Westbrook and Dryer (1981)
NO formation: thermal (Zeldovich) and prompt (de Soete, 1974) Arrhenius rate+ PDF(T) (RNA approach on the way)
Boundary conditions:
air inlet: the temperature is evaluated trough a subroutine as a function of exhaust gas temperature, on the basis of experimental data on the air pre-heater efficiency;
radiant tube: heat losses are evaluated through a subroutine based on conduction and radiation between coaxial cylindrical shields iterative solution
2 subroutines are needed to develop a self-sufficient model of the burner
CFD in combustion and flames: an IFRF perspective- L.Tognotti

34. CFD results of Burner n°1 (CH4-H2 fuel)
Temperature distribution – CFD results
Aair,in = 339 mm2
kR = 55%
Tmax = 2409 K
Aair,in = 25 mm2
kR = 143%
Tmax =2498 K
Aair,in = 62 mm2
kR = 237%
Tmax =2056 K
CH4-H2 fuel 20% by wt., 37% of thermal input)

35. CFD results of Burner n°1: NO emissions
NOx are suppressed by more than two orders of magnitude!
NOx decreases monotonically with R despite the peak in the Tmax vs. R profile

36. Original joint RANS/LES approach (Zimont):
RANS modelling is the main tool for the fluid dynamic analysis of industrial burner;
LES modelling is necessary for analysis of instantaneous structures of combustion;
Replacing RANS by LES is unlikely for simulations of many industrial combustors.
Original joint RANS/LES approach (Zimont):
The aim: To have an economic method for simulations of both average (RANS simulations) and instantaneous fields (LES).
The main idea: Not LES instead of RANS, but a joint simulation:
1. First step: RANS simulations of the averaged fields;
2. Second step: LES (which is based on the RANS results for modelling sugrid turbulence) for simulation of instantaneous fields showing subgrid smoothed turbulent structures and reaction zones. .

39. Gas turbines: possible configuration
Flame combustor
Fuel
Air
Multimonolithic Combustor
LPF = Lean Premixed Flame
Partially Catalytic Combustor
LPF
Hybrid Combustor
Fuel CH4
 6-6.5% vol. °C
T  2000°C
350°C
Turbine
Bypass air
Compressor
NOx emissions
secondary treatment of exhaust gases
Air
Fuel CH4
 3-4% vol.
Catalytic combustor
350°C
Turbine
T  °C
Compressor
NOx not present: primary measure of control
Air
ISTITUTO DI RICERCHE SULLA COMBUSTIONE, Napoli

40. Development of catalyst for catalytic combustion
Attività 4.2.1
(IRC-UNINA)
Sviluppo di sistemi catalitici
Washcoat
Active phase
ISTITUTO DI RICERCHE SULLA COMBUSTIONE, Napoli

41. Hydrogen burners (RIELLO) Attività 4.1.3
Progettazione e sperimentazione di un bruciatore atmosferico low NOx ad idrogeno
Attività 4.1.5
Sperimentazione di tecniche di combustione flameless per applicazioni residenziali
Attività 4.2.4
Progettazione e sperimentazione di un bruciatore atmosferico low NOx a matrice porosa

42. Project Oganisation

43. The IFRF – International: 146 member organisations
American Flame Research Committee
(AFRC)
British Flame Research Committee
(BFRC)
Australian Flame Research Committee
(AusFRC)
Finnish Flame Research Committee
(FFRC)
International Flame Research Foundation (IFRF)
German Flame Research Committee
(DVV)
Dutch Flame Research Committee
(NVV)
Italian Flame Research Committee
(CI)
Japanese Flame Research Committee
(JFRC)
IFRF is a Network of Combustion Related People Around 1200 people in 23 countries
French Flame Research Committee
(CF)
Swedish Flame Research Committee
(SFRC)
Associate Members Group
(AMG)

45. Capabilities of the IFRF
Isothermal plug flow reactor (IPFR)
100 KWT Furnace, 500 KWT Furnace
CASPER (6.5 MWt for liquid/gas burners)
FOSPER (FOrnace SPERimentale) (Furnace #1)
CIRO (100 kWt circulating fluidized)
SCR (Catalytic Denitrifier Ncm/h of flue gas)
Bagfilter, Electrostatic Precipitator
SPLIT (0.5-2 MWt gas turbine combustor, atmospheric)
Hitac/Flameless Combustors
Aerodynamic lab.
Optical Diagnostic lab.

46. Members Research Programme
Planning 2007/2009
Members Research Programme
IFRF Members were invited to consider five Research Topics (MRP1 to MRP5) that may be pursued using funding from ENEL-UNIPI, and to express preferences.
The topics are now building on the former IFRF MRP in areas such as solid fuels combustion characterisation, mathematical modelling and flameless combustion.
New (to IFRF) topic areas of micro-pollutants and micro-particulates are also proposed
Ranking for 34 Members
Combustion Modelling (132)
Solid Fuel Characterisation (101)
Hydrogen/syngas Production and Use (94)
Micro-pollutants- heavy metals (86)
Fate of micro-particulates from combustion sources(62)

47. MRP n.3: Hydrogen - Syngas Production and Utilisation
The following items are under discussion and it is planned – depending on the availability of funds - to set up research activities on the following issues: 1. Hydrogen-syngas production from coal and alternative fuel 1.1 Investigations on devolatilisation/gasification kinetics of coal and alternative fuel: modelling and basic experiments (IPFR + structural models) 1.2 Model development for integrated process simulation of coal -gasification 1.3 Experimental campaign on a coal-to-hydrogen pilot plant 2. Hydrogen- syngas utilisation 2.1 Low-NOx hydrogen combustion in gas turbine (CFD Modelling + Full-scale test) 2.2 Flameless hydrogen combustion (CFD Modelling + Pilot-scale test) 2.3 Micro-turbine and Catalytic combustion: experiments at lab-scale 47