Demonstration Plant Research Articles

Pumped thermal energy storage with heat pump-ORC-systems: Comparison of latent and sensible thermal storages for various fluids

To compensate for the recurring daily fluctuations of the power generation of renewable energies, energy storage systems are necessary that are able to adjust the time shift of the power generation to the required load profiles with high numbers of cycles and high capacity. Due to their independence from geographical and geological requirements, Pumped Thermal Energy Storages (PTES) are a possible form of energy storage in system-relevant orders of magnitude for these requirements. Compared to electric resistance heaters, the round trip efficiency can be significantly improved by using a heat pump in the PTES. A further improvement occurs when low-temperature waste heat from other processes or sources (such as solar or geothermal energy) is used for the heat pump. The use of most components of the heat pump for an Organic Rankine Cycle (ORC) for heat to power conversion drastically increases the cost efficiency of the storage concept, but requires both cycles to run on the same fluid. The goal of this work is to identify optimal fluids and operating parameters for the combined cycle. Both latent and sensible storage systems are considered for different fluids and are examined for their suitability for different operating conditions with a focus on the behaviour of cyclopentane, R1233zd(E), Novec 649 and R365mfc. The fluids and storage systems are evaluated by defining a reference case and by varying different parameters of this reference case. The simulations were performed using a custom Matlab® model and fluid data provided by REFPROP. With general conditions for small applications in the size of a demonstration plant with 20 kW electrical input power, power to power (ηP2P) efficiencies of over 80% are demonstrated. With simple sensible storage media, ηP2P efficiencies of 62% are achieved.

Managerial and organizational challenges encountered in the development of sustainable technology: Analysis of Swedish biorefinery pilot and demonstration plants

Pilot and demonstration plants (PDPs) perform critical tasks in the development of new sustainable technology by bridging basic knowledge generation and large-scale commercialization. Significant private and public funding has therefore been allocated to PDPs addressing climate change, pollution abatement technology and/or increased resource efficiency. After technology verification, PDPs typically struggle with evolving objectives, and reports of stalled or delayed development are common. Key problems may center on technical difficulties, but challenges of a non-technical nature are equally important, not least for the development of clean technology. This paper draws on a longitudinal case study of four PDPs used for advanced biorefinery technology development in Sweden and delineates the key managerial and organizational challenges that arise in and around such plants. By taking the actor networks around PDPs as the main unit of analysis, this paper gives a detailed description of various challenges, such as the division of responsibility for the operation and ownership of the PDPs, unclear roles and objectives, and the lack of specific competences and resources in the actor networks. One important conclusion is that improved knowledge about such challenges should increase the resilience of actor networks in and around PDPs, and also help shorten the formative phase of developing sustainable technology.

Issue Information

Cover Photograph: Image of Dr Lou Vance at the ANSTO Synroc Demonstration Plant in 2018 provided by ANSTO. image 2019 ACerS Ceramographic Exhibit & CompetitionCategory: SEM, 3rd Place image

Characterisation of Lactoferrin Isolated from Acid Whey Using Pilot-Scale Monolithic Ion-Exchange Chromatography

The aim of this study was to characterize the properties of lactoferrin (LF) obtained in a process developed for its isolation from acid whey derived from the production of fresh curd cheese, using a unique technology of ion-exchange chromatography on CIM® monolithic columns. The freeze-dried lactoferrin samples produced on the pilot plant (capacity 1 m3) were examined for the purity, iron-binding capacity, antibacterial activity, and pH- and temperature-stability. Apo-LF inhibited several tested strains (enterobacteria, Staphylococcus, Streptococcus salivarius) except clostridia, lactic acid bacteria, and bifidobacteria. Sample of LF intentionally saturated with Fe3+ lost its antibacterial activity, indicating the involvement of mechanisms based on depriving bacteria of an iron source. All samples, regardless of the iron-saturation level, exhibited stability in pH range 4.0 to 11.0. LF with higher iron content (A-value = 41.9%) showed better thermal stability. Heat treatment up to 72 °C/3 s did not reduce antimicrobial activity against E. coli O157: H7 tox-. Higher purity (above 91%), higher iron-binding capacity and higher inhibitory activity against E. coli O157: H7 tox- compared to some similar products from the market was observed. These results demonstrate a high potential of monolithic ion-exchange chromatography for industrial processing of acid whey as a source of LF that can be used in new products with high-added value. The upscaling of the process is ongoing on a demonstration plant (10–30 m3/day capacity).

Anaerobic membrane bioreactors (AnMBR) treating urban wastewater in mild climates

Feasibility of an AnMBR demonstration plant treating urban wastewater (UWW) at temperatures around 25–30 °C was assessed during a 350-day experimental period. The plant was fed with the effluent from the pre-treatment of a full-scale municipal WWTP, characterized by high COD and sulfate concentrations. Biodegradability of the UWW reached values up to 87%, although a portion of the biodegradable COD was consumed by sulfate reducing organisms. Effluent COD remained below effluent discharge limits, achieving COD removals above 90%. System operation resulted in a reduction of sludge production of 36–58% compared to theoretical aerobic sludge productions. The membranes were operated at gross transmembrane fluxes above 20 LMH maintaining low membrane fouling propensities for more than 250 days without chemical cleaning requirements. Thus, the system resulted in net positive energy productions and GHG emissions around zero. The results obtained confirm the feasibility of UWW treatment in AnMBR under mild and warm climates.

Life cycle assessment of wastewater reclamation in a petroleum refinery in Turkey

Wastewater reclamation in a petroleum refinery in Turkey was evaluated with life cycle assessment (LCA). The goal of the study was to determine whether or not refinery wastewater reclamation for different industrial purposes, namely boiler feedwater, cooling water and fire water, leads to an overall benefit across different environmental aspects, besides alleviating freshwater resources, when compared to current wastewater disposal practices. The basis for the assessment was the hypothetical scale-up of a demonstration plant tested with real wastewaters from November 2018 to May 2019 at the Izmit petroleum refinery operated by Tüpraş. This demonstration plant consisted of different treatment modules, including dissolved air flotation, ceramic membrane bioreactor, catalytic wet-air oxidation, advanced oxidation with ozone and hydrogen peroxide, and reverse osmosis. The LCA was conducted following consequential modelling principles, and six environmental indicators were analysed in detail at midpoint level: global warming, respiratory inorganics, marine ecotoxicity, aquatic eutrophication, freshwater consumption and non-renewable energy demand. All three reclamation scenarios (boiler, cooling, fire water) succeeded in achieving a life-cycle freshwater saving, of around 1 m3 freshwater saved per m3 refinery wastewater. Beneficial results were also obtained in marine ecotoxicity and aquatic eutrophication, where impact is reduced up to 90% and 84%, respectively. With regard to global warming and non-renewable energy demand, only the boiler feedwater application appeared to involve an improvement over wastewater disposal, showing a net reduction of 2.2 kg CO2-eq and 40 MJ per m3 wastewater, respectively, thanks to potential thermal energy savings. For cooling makeup water and fire water, impacts were between 2 and 2.5 times higher in these two indicators when compared to wastewater disposal. Finally, the indicator on respiratory inorganic effects, showed higher impact, by a factor 2 to 7, for all reuse scenarios, due to electricity demand, which is linked to the Turkish electricity production mix with a substantial contribution from coal power plants. Thus, the results reflect that achieving a product water of very high quality comes at the price of a high energy demand. Nevertheless, A sensitivity analysis shows that the environmental performance of all scenarios would improve to a great extent when shifting to an electricity mix with a higher share of renewables, as is the current trend in most European countries.

Electrical Loads and Power Systems for the DEMO Nuclear Fusion Project

EU-DEMO is a European project, having the ambitious goal to be the first demonstrative power plant based on nuclear fusion. The electrical power that is expected to be produced is in the order of 700–800 MW, to be delivered via a connection to the European High Voltage electrical grid. The initiation and control of fusion processes, besides the problems related to the nuclear physics, need very complex electrical systems. Moreover, also the conversion of the output power is not trivial, especially because of the inherent discontinuity in the EU-DEMO operations. The present article concerns preliminary studies for the feasibility and realization of the nuclear fusion power plant EU-DEMO, with a special focus on the power electrical systems. In particular, the first stage of the study deals with the survey and analysis of the electrical loads, starting from the steady-state loads. Their impact is so relevant that could jeopardy the efficiency and the convenience of the plant itself. Afterwards, the loads are inserted into a preliminary internal distribution grid, sizing the main electrical components to carry out the power flow analysis, which is based on simulation models implemented in the DIgSILENT PowerFactory software.

Solar-Energy Innovative and Sustainable Solution for Freshwater and Food Production for Lake Titicaca Islands

Drought and scarcity of water resources require innovative and sustainable solutions to secure water availability for poor people. Choice of solar energy for desalination is a promising and sustainable cost-effective alternative for improving high quality water supply. Today, almost all Latin American countries use different desalination technologies except for Bolivia. Bolivia has an arid to semiarid climate and suffers from salinity problems especially the Altiplano area. Thus, there is a need to introduce innovative solution using latest technologies such solar desalination at locations with scarcity of freshwater. This study suggests implementing a small desalination plant of about 10 m3/day as a demonstration plant and then successively extending the capacity. As well, it is suggested to build a solar energy system with bigger capacity to cater not only for the desalination plant, but also the excess energy to be benefit for homes, roads lighting, and other important purposes for the local community to improve life standard of the people.

Solar-Energy Innovative and Sustainable Solution for Freshwater and Food Production for Lake Titicaca Islands

Drought and scarcity of water resources require innovative and sustainable solutions to secure water availability for poor people. Choice of solar energy for desalination is a promising and sustainable cost-effective alternative for improving high quality water supply. Today, almost all Latin American countries use different desalination technologies except for Bolivia. Bolivia has an arid to semiarid climate and suffers from salinity problems especially the Altiplano area. Thus, there is a need to introduce innovative solution using latest technologies such solar desalination at locations with scarcity of freshwater. This study suggests implementing a small desalination plant of about 10 m3/day as a demonstration plant and then successively extending the capacity. As well, it is suggested to build a solar energy system with bigger capacity to cater not only for the desalination plant, but also the excess energy to be benefit for homes, roads lighting, and other important purposes for the local community to improve life standard of the people.

Dynamic Simulation of System Performance Change by PID Automatic Control of Ocean Thermal Energy Conversion

Near infinite seawater thermal energy, which is considered as an alternative to energy shortage, is expected to be available to 98 countries around the world. Currently, a demonstration plant is being built using closed MW class ocean thermal energy conversion (OTEC). In order to stabilize the operation of the OTEC, automation through a PID control is required. To construct the control system, the control logic is constructed, the algorithm is selected, and each control value is derived. In this paper, we established an optimal control system of a closed OTEC, which is to be demonstrated in Kiribati through simulation, to compare the operating characteristics and to build a system that maintains a superheat of 1 °C or more according to seawater temperature changes. The conditions applied to the simulation were the surface seawater temperature of 31 °C and the deep seawater temperature of 5.5 °C, and the changes of turbine output, flow rate, required power, and evaporation pressure of the refrigerant pump were compared as the temperature difference gradually decreased. As a result of comparing the RPM control according to the selected PID control value, it was confirmed that an error rate of 0.01% was shown in the temperature difference condition of 21.5 °C. In addition, the average superheat degree decreased as the temperature difference decreased, and after about 6000 s and a temperature decrease to 24 °C or less, the average superheat degree was maintained while maintaining the superheat degree of 1.7 °C on average.

Design and analysis of a low-carbon lignite/biomass-to-jet fuel demonstration project

Biomass-derived synthetic jet fuel with low net greenhouse gas emissions can help decarbonize aviation. Demonstration projects are required to show technical feasibility and give confidence to investors in large commercial-scale deployments. Most previous literature focuses on assessing future commercial-scale systems, for which performance and costs will differ considerably from demonstration projects. Here, a detailed analysis is presented for a first-of-a-kind demonstration plant that would be built in the Southeastern US. The plant, which cogasifies biomass and lignite and captures CO2 prior to Fischer-Tropsch synthesis, was designed and simulated using Aspen Plus. The process heat recovery system was designed using a systematic optimization method. Lifecycle analysis was used to assess net greenhouse gas emissions. Capital and operating cost estimates were developed in collaboration with a major engineering firm. The plant produces 1252 barrels per day (80% jet fuel), exports 15 MWe (net), and has a net energy efficiency of 35.8% (lower heating value). Captured CO2 (1326 t/d) is sold for use in enhanced oil recovery. With biomass coming from sustainably-managed pine plantations, net lifecycle greenhouse gas emissions are well below those for petroleum jet fuel. The estimated range of capital required to build the plant is 3875–5762 $/kWth of feedstock input (2015$). As expected for a small demonstration designed to minimize technological risks, subsidies are required for the jet fuel product to compete with petroleum jet fuel. Technology innovations, learning via construction and operating experience, and larger plant scales will improve the economics of future commercial plants.

Sustainable sediment management in coastal infrastructures through an innovative technology: preliminary results of the MARINAPLAN PLUS LIFE project

PurposeThe paper aims to show the preliminary monitoring and field test results of the innovative technology tested in the framework of the MARINAPLAN PLUS LIFE project for sustainable management of sediment in harbour areas. The technology is based on a patented jet pump that will be able to keep the seabed at a certain level over the time through a continuous removal of silting sediments.Materials and methodsPreliminary field tests were performed to optimise the design of the demo plant and a monitoring plan was devised to evaluate the technical, economic and environmental impacts of the technology, in particular in comparison with dredging.Results and discussionThe preliminary tests showed promising results in terms of efficacy and efficiency of the sediment by-passing device. At the maximum sediment removal capacity, the ejector tested in Cervia showed a sediment flow rate of about 2 m3 h−1, with an electric consumption of about 3.5 kW, and an influence diameter of about 5–7 m, after 15 days of working operation. On the basis of the preliminary results, a 10-ejector demonstrator plant has been designed and realised, and it is now in operation. The analysis of sediment and marine flora and fauna in the installation area in comparison with control areas indicates the negative impact of cyclic dredging in the harbour inlet area.ConclusionsThe innovative technology promoted by the MARINAPLAN PLUS LIFE project is a promising solution to manage sediment siltation in harbour areas through a cost-effective and low environmental impact technology. The monitoring of the demo plant operation is fundamental to fully validate the technology and to demonstrate its efficacy and sustainability.

Trends in tidal power development

Tidal energy has been around for almost 2, 000 years, as the first Tide Mills date the Romans times. Tidal power generation then emerged in the 1960s, with the construction of the 240 MW La Rance power station, a still working example of good renewable energy initiative, permitting electricity production at very competitive costs since now more than 54 years. Unfortunately, apart from the construction in 2011 of a similar plant based on the tidal range technology, the 254 MW Sihwa Lake power station, almost nothing else happened in the real world for tidal energy, apart from very small or demonstration plants. While the future is certainly towards tidal streams/currents technologies rather than tidal range technologies, as tidal currents turbines may also be used for oceanic currents installations, these technologies are still in their infancy, as apart from their theoretical performance, every other aspect of a submerged power plant operation needs further developments.

Water reuse and recycling in Japan — History, current situation, and future perspectives

Water reuse is an effective option all over the world for saving water resources, reducing environmental impacts, and reducing the costs and energy involved in water resource management. In Japan, non-potable water reuse has been implemented in several cities since the 1980s, mainly for urban applications such as toilet flushing, urban stream water augmentation, and landscape irrigation. However, utilization of reclaimed water is still limited in Japan due to the inadequate quality standards for reclaimed water and the high energy consumption of water reclamation facilities. From 2010 to 2015, a Core Research for Evolutional Science and Technology (CREST) project was carried out in Japan to develop energy-efficient water reclamation processes utilizing membrane technologies and ozonation processes. A comprehensive evaluation of the process performances and the economic feasibility showed that the UF ​+ ​UV (ultrafiltration ​+ ​ultraviolet radiation) process provided removal of viruses to a level adequate for water reuse for agricultural purposes at low cost. Based on the results from the CREST project, a demonstration plant incorporating the UF ​+ ​UV process was constructed at the Itoman wastewater treatment plant in Okinawa to evaluate performance in terms of virus removal and to implement agricultural water reuse. Other innovative technologies are also under development in Japan to reduce the cost and energy involved in water reclamation. This paper introduces the history, current situation, and future perspectives of water reclamation and reuse in Japan.

Current status of CO2 chemical absorption research applied to CCS: Towards full deployment at industrial scale

This work provides a wide overview of the state-of-art of the CO2 chemical absorption applied to Carbon Capture and Storage (CCS) technology. The objective is not only to provide the current status of the technology and the research and development activities carried out towards its deployment in the CCS field, but also to identify the future directions and knowledge gaps. A summary of the conventional solvents used for acid gas removal and novel solvent formulations specifically adapted to new challenges such as fossil-fuels power plants and industrial processes was reported. Novel configurations from the conventional CO2 absorption-desorption layout were summarized and their impact on the operational performance and the reboiler duty was further evaluated. Novel opportunities offered by CO2 concentrated flue gas derived from partial oxy-combustion were further discussed in the final section. A large review of the published data from pilot plants has been done to facilitate the final comparison between the current status of post-combustion and novel partial oxy-combustion configurations. Demonstration plants currently available and the commercial solutions proposed by the most important companies were briefly described. CCS pilot plants via chemical absorption have been executed in last decades reaching several CO2 capture capacities up to 80 t CO2/day. Commercial scale plants have been recently developed, being US and China the countries which lead the investment funds. The most important commercial scale demo plants, namely Boundary Dam and Petra Nova, were also described. Nevertheless, there were still many countries which need to bet for CCS at large scale.

Microbial production of 2,3-butanediol for industrial applications.

2,3-Butanediol (2,3-BD) has great potential for diverse industries, including chemical, cosmetics, agriculture, and pharmaceutical areas. However, its industrial production and usage are limited by the fairly high cost of its petro-based production. Several bio-based 2,3-BD production processes have been developed and their economic advantages over petro-based production process have been reported. In particular, many 2,3-BD-producing microorganisms including bacteria and yeast have been isolated and metabolically engineered for efficient production of 2,3-BD. In addition, several fermentation processes have been tested using feedstocks such as starch, sugar, glycerol, and even lignocellulose as raw materials. Since separation and purification of 2,3-BD from fermentation broth account forthe majority of its production cost, cost-effective processes have been simultaneously developed. The construction of a demonstration plant that can annually produce around 300 tons of 2,3-BD is scheduled to be mechanically completed in Korea in 2019. In this paper, core technologies for bio-based 2,3-BD production are reviewed and their potentials for use in the commercial sector are discussed.

The case for a tortoise approach to US nuclear research and development

The future role of nuclear power in decarbonization of the US electricity grid is uncertain. Large light water plants have proven challenging to deploy, and the existing nuclear fleet is under market pressure. A new cadre of developers, supported by the US Department of Energy, is pressing for an accelerated path to deployment of new nuclear designs to address the climate challenge and maintain the nuclear industrial base. However, an examination of market dynamics and the ongoing pace of low carbon technology transition portend significant challenges for these vendors. Our analysis indicates that the current advanced reactor research and development paradigm is unlikely to yield multiple technology options in a timeframe that matters and argues for a slower and steadier “tortoise” approach. Using an optimization model we demonstrate that a slower, structured approach across a broad portfolio of technologies will better align nuclear development with a possible mid-century market opening. By allowing additional development time, building multiple demonstration plants, and operating these new designs for extended periods, it is more likely that there will be competitive technologies that can meet the future economic and technical requirements for widespread nuclear deployment should the technology be required in decarbonization efforts.

Topsoe to build demonstration plant to produce cost-competitive CO2-neutral methanol from biogas and green electricity

Topsoe to build demonstration plant to produce cost-competitive CO2-neutral methanol from biogas and green electricity

Standard Lithium building plant

Standard Lithium has began installing modules for its lithium extraction facility in El Dorado, Arkansas. The demonstration plant for the company’s process will take in 11.4 m3/h of tail brine from...

(Invited) Large Scale PEM Electrolysis for Industrial Applications

Polymer electrolyte membrane (PEM) based water electrolysis for hydrogen production is widely considered as a key technology to decarbonize our fossil-based energy system. Due to its highly dynamic behavior PEM electrolyzer systems accomplish the requirements to be operated with renewable energy-based electricity such as wind or PV power. The production of chemical energy carrier such as hydrogen enables the integration of renewable energy into industrial processes and mobility and therefore sector coupling. Changes need to be made in energy production to achieve the long-term goal of the Paris agreement, to keep global warming below 2°C [1], and to reach the CO2 target by 2050 whereas hydrogen could make up to 20% of the abatement [2]. Reaching this target, a transition of the fossil-based hydrogen production towards green hydrogen produced by electrolysis is an essential factor. Therefore, PEM electrolyzer systems have to reach industrial relevant sizes and significant cost reduction. Siemens Hydrogen Solution has released its next generation of PEM electrolyzer system Silyzer 300 in 2018. By choosing a highly modular concept, Siemens AG is offering hydrogen generation plants from 10 to 100 MW based on PEM technology. It allows the full utilization of economy of scale effects also for customized solutions. However, in order to achieve the expansion targets that are published in various studies of several hundreds of Megawatts per year, it is essential to achieve further progress in regards to cost reduction, efficiency increase and overall hydrogen production plant optimization. Together with our partners in H2Future, an FCH JU funded project, a demonstration plant is currently being built and will be operated at the largest steel production site of voestalpine Group in Linz, Austria. In a nutshell, the fundamental goal of H2Future is to demonstrate that an industrially integrated PEM electrolyzer system is able to produce green hydrogen and provides grid services at the same time. [1] https://ec.europa.eu/clima/policies/international/negotiations/paris_de[2] Hydrogen Council, Hydrogen Scaling up: A sustainable pathway for the global energy transmission, Nov. 2017 Figure 1