Highly efficient Power Production by green Ammonia total Oxidation in a Membrane Reactor

Project Information

HiPowAR

Grant agreement ID: 951880

DOI

10.3030/951880

Project closed

EC signature date 30 June 2020

Start date 1 September 2020

End date 31 December 2025

Funded under

• EXCELLENT SCIENCE - Future and Emerging Technologies (FET)

Total cost

€ 3 999 851,25

EU contribution

€ 3 999 851,25

Coordinated by

LEIBNIZ-INSTITUT FUR PLASMAFORSCHUNG UND TECHNOLOGIE EV
Germany

Periodic Reporting for period 2 - HiPowAR (Highly efficient Power Production by green Ammonia total Oxidation in a Membrane Reactor)

Reporting period: 2022-03-01 to 2023-08-31

Summary of the context and overall objectives of the project

The European Union (EU) is committed to reducing greenhouse gas emissions by 55% by 2030 and entirely by 2050. The energy and transport sectors stand out as significant contributors to these emissions. The overarching objective of the HiPowAR project is to pioneer a groundbreaking technology for the direct energy conversion of renewable ammonia (NH3) fuel into power. This technology aligns with the EU's green objectives while addressing the pressing need to transition towards sustainable energy solutions for localized power generation and transportation, e.g. in the shipping and railway industries.
Renewable ammonia, a carbon-free synthetic fuel, boasts nearly twice the energy density by volume compared to hydrogen (H2), making it easier to store, ship, and distribute. A global economy centred on green ammonia promises reliable, carbon-free energy supplies. Distinguishing itself from conventional, incremental approaches, HiPowAR focuses on a fundamentally novel concept, implemented within a single device. In a pressurized membrane reactor (MR), NH3 is oxidized at high pressure, employing ceramic MIEC (Mixed Ionic Electronic Conductor) membranes that permit the passage of oxygen (O2) exclusively. The project involves experimental investigation of the membranes and of the system, while concurrently developing simulation models to predict NH3 conversion rates, power output, and system performance. The outcome of this analysis will lead to an optimized configuration for future full-scale deployment. Critical technical specifications for commercial devices will be identified, ensuring the seamless technology transfer of HiPowAR.
In evaluating economic feasibility and competitiveness, HiPowAR exhibits several key advantages: higher efficiency (up to 60%) while striving for low reactor investment costs and a steeper cost decrease for larger systems compared to fuel cells and combustion engines. The assessment also encompasses ecological considerations related to decarbonisation, as well as an examination of potential risks associated with the use of ammonia.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Significant progress has been made in several specific objectives to realize this novel technology. To develop MIEC membranes suited for NH3 combustion, state-of-the-art MIEC materials BSCF and CSFM were prepared and used to manufacture membrane samples. A novel tubular membrane geometry was developed enabling a much simpler feed gas management in the membrane reactor. To minimize the thermal shock stability, the outer diameter of the membrane was kept as small as possible (4 mm). At the same time, the wall thickness was reduced to 0.3 mm to increase the oxygen flux thought the membrane. The inner air inlet tube is made of the same ceramic material as the membrane (BSCF or SCFM) and is internally supported by guide bars. The implemented new design prevents chemical reactions between different materials, minimizes mechanical stress, and decreases the membrane manufacturing costs. However, the first tests performed at 850°C and 50 bar have shown an insufficient mechanical stability of the membrane tube. This problem will be solved by doubling the wall thickness of the membrane. Furthermore, work was carried out for the upscaling of membrane production at 25l Kneader and 50mm twin screw extruder. In order to achieve consistent quality during the scaling process, the plasticizing process and receipt and the technological parameters were adapted and optimized. First tests for ammonia total oxidation using single membrane tubes were completed successfully at environmental pressure between 850 and 950 °C.
Detailed temperature and stress analyses are conducted to validate the reactor design. Experiments assessing the membrane sealing capabilities under operating conditions - a critical point of the reactor design – as well as experiments on the membrane design were conducted. The experiments verify the suitability of O-ring sealing for operating parameters of the reactor. The finalization of other test rig components is completed, and FEM analyses ensure their functionality and structural integrity. Operating parameters of main test rig components are defined and the test rig layout is presented.
The definition of the optimal design for the HiPowAR system is aided by the development of a simulation tool. Baseline system configurations have been defined. Thermodynamic simulations of the baseline configurations revealed that the system efficiency is underwhelming compared to initial expectations. Therefore, advanced configurations are under development to maximize the system efficiency, including reheating, regenerative bleeding, and addition of a bottoming cycle. The latest simulations suggest that a system efficiency around 60% is possible for advanced configurations. The HiPowAR system can produce water as a by-product, as up to 98% of the water embedded in the input NH3 can be recovered. Since the membrane reactor is the most critical and innovative component of the plant, a detailed numerical model has been developed to simulate the oxygen permeation process. The model will be calibrated and validated using experimental data.
Cost estimations of the HiPowAR system and competing technologies are performed, considering the early stage of development and the continuously improvements in HiPowAR reactor and system design. Continuously updated cost estimations during the entire project duration ensure state of the art economic comparability in a fast-changing environment. With increased knowledge about feasible plant designs, more detailed economic analyses will be performed for specific plant designs in a techno-economic assessment.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The HiPowAR technology represents a significant advancement beyond the state of the art, with the potential for substantial socio-economic and broader societal impacts. The technology enables the direct use of ammonia yielding higher efficiency and lower cost compared to state-of-the-art SOFCs, ICEs or even PEMFC (Polymer Electrolyte Membrane Fuel Cell). Key highlights of the HiPowAR technology:
- High Efficiency and Low Costs: HiPowAR achieves high efficiency in the direct energy conversion of ammonia to power, potentially surpassing existing alternatives. This leads to a more sustainable energy solution with an expected lower operational cost.
- Reduced Carbon Footprint
- Increased Load Flexibility: Compared to ammonia-fed fuel cells, HiPowAR has a comparable efficiency while providing greater load flexibility. It enables direct mechanical propulsion of vehicles with minimal energy conversion losses.
- Enhanced Fuel Utilization: In contrast to SOFCs, HiPowAR boasts better fuel utilization, eliminating the need for fuel reformation or afterburner processes through the membranes’ significantly higher oxide ion conductivity and oxygen throughput.
- Simplified Design: The technology eliminates the complexities associated with building and maintaining electrolytes coated with electrodes, interconnection, stack joining, and other intricate components, streamlining the system.
- Economic Scalability
In conclusion, HiPowAR's breakthrough technology has the potential to transform the renewable energy landscape, reducing greenhouse gas emissions and contributing to a sustainable future. With its high efficiency, cost-effectiveness, and environmental benefits, it stands as a promising solution for a wide range of applications, from power generation to transportation.

HiPowAR membrane reactor design

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