FutureGen -Tomorrow's Clean Energy Interactive and Combined Economic Drivers
Resoure: Power Fuels: Fossil Fuels: Gas, Oil and Coal Biomass: Wood, AG and Waste Products Stationary: Carbon and Carbon Carriers Transportation: Hydrogen and Hydrogen Carriers High Efficiency Reduced CO2 Emission: Sequestration

Converters: Environment:

Meyer Steinberg, Consultant BNL, Upton, NY 11973 (msteinbe@bnl.gov) MSA, Inc., Melville, NY 11757 (mrsteinb@optonline.net) Tel. (631)427-0768 Fax. (631)427-0590
An Innovative Highly Efficient Combined Cycle Fossil and biomass Fuel Power Generation and Hydrogen Production Plant with Zero CO2 Emission
By Meyer Steinberg, Consultant Brookhaven National Laboratory Upton, NY 11973-5000 (631) 427-0768 (phone) (631)427-0590 (fax) Msteinbe@bnl.gov March 2003
Benefits of a Carbon Fuel Cell
Utilizes all the Carbon Energy in Fossil Fuels Directly and Efficiently The Thermodynamic Efficiency of a Carbon Fuel Cell is 100%; Entropy Change is zero F/H = 1.002 (25-1000C) The Thermodynamic Efficiency of a Hydrogen Fuel Cell is only 70%; Entropy Change is Large F/H =0.700 at 1000C The Activity of the C Fuel and CO2 Product is Unity Allows Full Utilization of C Fuel in One Pass. The Activity of the H2 Fuel and H2O Product in a Hydrogen-Fuel Cell is Less than Unit Resulting in Only 80% Utilization in One Pass A Molten Salt (Carbonate) Carbon Fuel Cell Operating at 750C Has Achieved 86% Thermodynamic Efficiency Power Densities of 1 Kw/m2 has been Achieved Concentrated CO2 is Evolved at the Anode Ready for Sequestration O2 from Air is Consumed at the Cathode Forming Carbonate Ion which is Transported through the Molten Salt Electrolyte to the Anode
Processes for Conversion of Fossil Fuels and Biomass to Carbon
1. Thermal Black from Natural Gas 2. Furnace Black from Oil 3. Petroleum Coke from Residual Oil 4. Hydrocarb Process from Coal and Biomass Hydrogenation followed by Thermal Decomposition of Methane 5. Plasma Black from Fossil Fuels and Biomass
Aerial view of the $65 million Karbomont Montreal-East facility, producing 20,000 T/year CARBON BLACK and 2500 million cubic ft/year HYDROGEN operating on natural gas and oil. (We are proposing to operate this process with coal after performing bench scale research with a laboratory palsma arc.)
Benefits of Hydrogen Plasma Black Reactor (HPBR)
1. Hydrogen Plasma is very efficient in cracking carbonaceous fuels to carbon, hydrogen and CO. 2. The reactor is flexible operating with different fuel feedstocks and is modular in design. 3. Thermal reaction temperatures of approximately 1500C is readily achieved. 4. Thermal Decomposition (cracking) Conversion is complete in one pass. 5. Best way of injecting enthalpy into the system and removing carbon: No heat transfer surface No combustion gases 6. Process Efficiency reaches 60% based on enthalpy of cracking. 7. Thermal Efficiency to products, C, H and CO reaches >90%.
Benefits of Matching Hydrogen Plasma Black Reactor (HPBR) with Direct Carbon Fuel Cell (DCFC)
1.The efficient generation of electrical energy from carbon in the DCFC can be supplied to and efficiently used in the HPBR. 2.The carbon efficiently generated in the HPBR can be efficiently used in the DCFC. 3.The fluid molten carbonate electrolyte in the DCFC can be effectively used to capture the carbon from the hydrogen stream in the HPBR. 4.The high temperature enthalpy in the HPBR (1500C) can be conserved in the DCFC (800C) 5.Modular design of the HPBR can be matched with the modular design of the DCFC. 6.The hydrogen from the HPBR can either be used in the SOFC for power generation or sold for the hydrogen fuel market.

DC Power

H2 Product

N2 SOFC 900oC

Recycle H2

Natural Gas CH4 or Oil

HPBR 1500oC

C 60% Proc.

Molte n Salt
H2O Steam Hot CO2 DCFC 750oC
CO2 for Sequestration Turbo-Gen. SRC 550oC N

C-Molten Salt Slurry

Condensed H2O

AC Power

Feed Back DC Power HPBR - Hydrogen Plasma Black
Reactor Natural Gas CH4 = C + 2H Oil CH1.7 = C + 0.85 H2 DCFC - Direct Carbon Fuel Cell C + O2 = CO2 (CO3= Ion Transport) SOFC - Solid Oxide Fuel Cell H2 + 1/2 O2 = H2O (O= Ion Transport) SRC - Steam Boiler Rankine Cycle
Figure 3 - Natural Gas or Oil Fueled Combined Cycle Hydrogen Plasma Black Reactor (HPBR) with Direct Carbon Fuel Cell (DCFC), Solid Oxide Fuel Cell (SOFC) and Backend Steam Rankine Cycle(SRC) Power Generation

H2 + CO2 Prod.

DC Power N2

Recycle H2 + CO H2

H2 + CO

WGS 450oC

H2 + CO2

SOFC 900oC

56% Hot H2O + CO2

H2O + CO2

CO2 for Sequestration

Turbo-Gen.

Coal or Biomass

PDR 1500oC Molten Salt

Ash + S Hot CO2

SRC 550oC

DCFC 750oC

Carbon/Slurry

Feed Back DC Power
HPBR - Hydrogen Plasma Black Reactor Lignite Coal CH0.77O0.24 = 0.76C + 0.24 CO + 0.385 H2 Kentucky Bit. Coal CH0.81O0.08 = 0.92 C + 0.08 CO + 0.40 H2 Biomass: CH1.38O0.59 = 0.41 C + 0.59 CO + 0.69 H2 WGS - Water Gas Shift Lignite 0.24 CO + 0.24 H2O = 0.24 CO2 + 0.24 H2 Bituminous 0.08 CO + 0.08 H2O = 0.08 CO + 0.08 H2 Biomass: 0.59 CO + 0.59 H2O = 0.59 CO2 + 0.59 H2 SOFC - Solid Oxide Fuel Cell H2 + 1/2 O2 = H2O (High Transport) DCFC - Direct Carbon Fuel Cell C + O2 + CO2 (CO3= Ion Transport) SRC - Steam Boiler Rankine Cycle
Figure 4. Coal or Biomass Fueled Combined Cycle Plasma Composition (PDR) with Direct Carbon Fuel Cell (DCFC), Hydrogen Solid Oxide Fuel Cell (SOFC) Backend Steam Rankine Cycle (SRC) Power Generation
Combined Cycle Fossil and Biomass Fuel Power Generation and Hydrogen production
Unit HPBR Hydrogen Plasma Black Reactor Converts FF to hydrogen and Carbon DCFC Direct Carbon Fuel Cell Converts Carbon to Electric Power SOFC Solid Oxide Fuel Cell Converts Hydrogen to Electric Power SRC Steam Rankine Cycle Converts Steam to Electric Power Max. Efficiency % Proc. Eff. 56 38
Very High Efficiency Combined Cycle Fossil and Biomass Fuel Power Generation HPBR/DCFC/SO FC/SRC
Fuel Natural Gas Crude Oil N. Dakota/Lignite Coal Kentucky Bituminous Coal Biomass -Wood HHV Thermal Efficiency -% 74.1 84.1 83.3 81.8 69.5 CO2 emission * Reduction -% 48.7 56.5 54.4 53.6 (100.0)
*CO2 Reduction from Conventional Steam Plant at 38% HHV Efficiency
Innovative High Efficiency Power and Hydrogen Generation Fossil Fuel Combined Cycle
Hydrogen Plasma Black Reactor (HPBR) in Combination with Direct Carbon Fuel Cell (DCFC)
Steam Water Gas Shift Reactor (WGS) (Only for Coal and Biomass) H2 CO Gas Oil Coal
CO2 for Sequestration H2 Hydrogen
Electric Power Anode Hydrogen Plasma Black Reactor (HPBR) 60% P. Eff. Ash S Carbon C Direct Carbon Fuel Cell (DCFC) 90% Eff. CO2 for Sequestration Total Thermal Eff. H2 + Power = >90% Cathode Air
Advanced High Efficiency Hydrogen and Electric power Production
HPRB/DCFC/SRC Combined Cycle
Fuel Natural Gas N. Dakota/Lignite Coal Biomass (wood) Hydrogen Production Efficiency % 64.2 38.3 77.1 Electric Power Efficiency % 25.8 52.9 12.0 Total Efficiency % 90.0 91.2 89.1
Unit HPBR Hydrogen Plasma Black Reactor Converts FF to Hydrogen and Carbon DCFC Direct Carbon Fuel Cell Converts Carbon to Electric Power SOFC Solid Oxide Fuel Cell Converts Hydrogen to Electric Power SRC Steam Rankine Cycle Converts Steam to Electric Power Max. Capital Cost Range -$/KW Efficiency % Min. Max. Proc. Eff. 400

CONCLUSIONS

The Hydrogen Plasma Black Reactor (HPBR) is an efficient Fossil Fuel and Biomass Converter supplying carbon for the highly efficient Direct Carbon Fuel Cell (DCFC). The Integrated Combined Cycle (ICCPH) for hydrogen and Electricity production can reach into 90% thermal efficiency. The ICCP for electricity using hydrogen in a Solid Oxide Fuel Cell (SOFC) and carbon in the DCFC can reach into the 70 to 80% thermal efficiency which is double that of conventional steam plants. A major environmental benefit of ICCPH is that the CO2 emission is significantly reduced in some cases by as much as 77% compared to conventional power and hydrogen production plants. Within the range of current costs of fossil fuel and projected capital cost of fuel cells, the estimated ICCP production costs are lower that with current conventional hydrogen and power plant costs. The coproduct feature of ICCPH allows flexibility in marketing competition between hydrogen and electricity.