Methods for operating solar-thermochemical processes
10801756 ยท 2020-10-13
Assignee
Inventors
Cpc classification
F24S2201/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S90/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E60/36
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F24S50/40
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/40
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
F24S90/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S20/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C01B3/06
CHEMISTRY; METALLURGY
Abstract
Methods for controlling or operating solar thermochemical reactions process that maximize the two-step thermochemical energy cycle efficiency by a combination of pressure and temperature swing are disclosed.
Claims
1. A method of operating a thermochemical reactor system comprising: setting a thermal reduction temperature, pressure and oxide mass flow for an oxide in the thermochemical reactor; setting an oxidation temperature and oxygen partial pressure in the thermochemical reactor system for a selected feed stream; and operating the thermochemical reactor system with the set thermal reduction temperature, pressure and oxide mass flow for an oxide in the thermochemical reactor and the set oxidation temperature and oxygen partial pressure in the thermochemical reactor system; where an amount of heat to satisfy the oxidation temperature is equal to an amount of heat provided by the oxide mass flow and the thermal reduction temperature.
2. The method of claim 1, wherein the feed stream is carbon dioxide.
3. The method of claim 1, wherein the feed stream is water.
4. The method of claim 3, wherein the oxidation temperature is red is equal to a steam generation for water at the set oxygen partial pressure.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Embodiments of the present invention are illustrated by way of example, and not limitation, in the figures of the accompanying drawings in which:
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
DETAILED DESCRIPTION
(10) The present disclosure is directed to methods for conducting a two-step thermochemical cycle at maximum energy efficiency by controlling solar thermochemical reactions and designing and operating a reactor that drives the two reactions through an appropriate combination of pressure and temperature swings. The term temperature swings, as used herein, refers to the situation wherein the two different reactions (oxidation and reduction) are carried out at different temperatures so that the thermodynamic equilibrium state of each of is more favorable. The difference in temperature between the high temperature (oxide reduction) and low temperature (reoxidation) step is the temperature swing. In the following description, numerous details are set forth. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without these specific details. In some instances, well-known methods and devices are shown in block diagram form, rather than in detail, to avoid obscuring the present invention. Reference throughout this specification to an embodiment means that a particular feature, structure, function, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. Thus, the appearances of the phrase in an embodiment in various places throughout this specification are not necessarily referring to the same embodiment of the invention. Furthermore, the particular features, structures, functions, or characteristics may be combined in any suitable manner in one or more embodiments. For example, a first embodiment may be combined with a second embodiment anywhere the two embodiments are not mutually exclusive.
(11) The terms coupled and connected, along with their derivatives, may be used herein to describe structural relationships between components. It should be understood that these terms are not intended as synonyms for each other. Rather, in particular embodiments, connected may be used to indicate that two or more elements are in direct physical or electrical contact with each other. Coupled may be used to indicated that two or more elements are in either direct or indirect (with other intervening elements between them) physical or electrical contact with each other, and/or that the two or more elements co-operate or interact with each other (e.g., as in a cause and effect relationship).
(12) The reactive particles applicable to the systems and techniques described herein may generally be of any type known for thermochemical reactions that are further suitable for conveyance by the systems and techniques described herein. In an embodiment, the reactive particles may be metal oxides, for example, but not limited to binary, ternary, and quaternary metal oxides, doped or undoped spinels, perovskites, brownmillerites, or other particles including a material having a composition capable of cyclic redox reactions. In this disclosure, exemplary embodiments utilizing a metal oxide (MO.sub.x), such as ceria (CeO.sub.2), ferrites, manganites, cobaltites, perovskites and the like are disclosed, however, alternative embodiments may employ any known particle composition capable of similar cyclic redox reactions. Reactive particles applicable to the systems and techniques described herein may also vary in size significantly with smaller sizes having higher surface/volume ratios improving reaction rates, but potentially being more susceptible to sintering and/or melting. For one exemplary ceria particle embodiment, particle size is between about 5 m (microns) and 500 m (microns).
(13) Although the reactive particles are not consumed significantly with each reaction cycle in the exemplary embodiments described herein, one of skill in the art will note the systems and techniques described herein enable particle continuous addition and extraction and are therefore readily adaptable to embodiments where the reactive particles may be consumed (e.g., attritted or volatilized) and replenished. Reactive particles applicable to the systems and techniques described herein may be a solid media of homogenous or heterogeneous composition (e.g., carrier media coated with reactive media) and of various porosity.
(14) The two step process may be applied to various two-step thermochemical cycle processes, such as, but not limited to solar fuel production, energy storage, and air separations. In an embodiment, the two-step thermochemical cycle is for solar fuel production, and may be a water splitting process or a carbon dioxide splitting process. In water splitting, the reduced metal oxide is reoxidized with steam at a specific temperature to yield H.sub.2. Some steam may be unreacted. The newly oxidized material is separated from the steam/H.sub.2 gaseous environment and is then thermally reduced by raising the temperature, lowering the oxygen partial pressure, or as described herein a combination of both. The evolved oxygen is pumped or swept away and the material is then ready for reoxidation with steam after the temperature is lowered as prescribed. If material flow through the cycle is continuous, the heat released during cooling may be recuperated to help drive thermal reduction. The net result of the process is that a combination of heat and oxygen pressure manipulation split water into separate streams containing H.sub.2 and O.sub.2. In carbon dioxide splitting, the process is entirely analogous with CO.sub.2 filling the role of H.sub.2O, and CO and O2 being the products.
(15) The disclosed methods determine the operating conditions and control parameters for operating a two-step thermochemical cycle at a point wherein the largest fraction of solar energy is converted to chemical energy.
(16) The methods determine the preferred combination of temperature swing and pressure swing between the reduction and oxidation steps for a cyclic two-step thermochemical process for a given set of the reduction temperature, and the effectiveness of recuperation of heat from the gaseous and solid streams. The preferred combination is that which provides the greatest chemical energy output per unit solar energy input. The thermal reduction temperature will typically be at or near an upper limit determined by materials or system limitations while the recuperation will be variable based on design and cost considerations for example; foregoing recuperation is one possible configuration. The methods are applicable to any solid phase metal-oxide system and any reactor embodiment that includes the option of both temperature and pressure swing.
(17) The methods for given reactive material include the following steps: 1. Determine the thermal reduction temperature based on materials limitations or other constraints, e.g. optimizing thermal receiver performance. 2. Determine the operating pressure (oxygen partial pressure) in the thermal reduction step. 3. Determine the solid-solid and gas-gas recuperation efficiencies. 4. Calculate the optimum temperature for the oxidation step. 5. Iterate/repeat to develop efficiency map as a function of reduction temperature, temperature swing, pressure swing, and recuperation efficiencies. 6. For water splitting, the preferred oxidation temperature is that wherein the oxide heating and steam generation heat requirements are equal or approximately equal. 7. Performance/efficiency mapping can be embedded into larger system model including the solar field, receiver, etc. to determine preferred thermal reduction temperature for overall system efficiency. 8. Performance/efficiency mapping can be embedded into larger system cost models to determine preferred configuration of thermal recuperation, pump sizes, etc. that gives the largest amount of stored chemical energy per unit of capital cost.
(18) The methods for operating the two-step thermochemical cycle process are further disclosed by referencing a two-step solar thermochemical reactive metal oxide water splitting cycle discussed below.
(19) Reactions (1) and (2) below, generically describe a two-step thermochemical cycle for H.sub.2 production via water splitting, based on a reactive metal oxide (MO.sub.x). Reaction (1) is an endothermic thermal reduction of the oxide carried out at a temperature T.sub.TR and pressure P.sub.TR. Reaction (2) is the mildly exothermic reoxidation of the reduced oxide with H.sub.2O, at temperature T.sub.WS, which yields H.sub.2 and restores the oxide to its initial state. In carbon dioxide splitting, the process can also be used to produce CO from CO.sub.2 in reaction (2). The sum of the two reactions is heat-driven H.sub.2O splitting, described by reaction (3):
(20)
(21) Here, .sub.TR and .sub.WS are the extents of reduction of the oxide following the thermal reduction and water splitting steps. Their difference, =.sub.TR.sub.WS, is the reversible oxygen capacity, as realized in the cycle. The oxygen partial pressure for the reduction reaction is p.sub.O2.
(22) At any temperature the Gibbs free energies of the above reactions are related:
G.sub.1=G.sub.3G.sub.2(4),
meaning that reactions (1) and (2) are thermodynamically spontaneous only in distinct and non-intersecting regions, i.e. G.sub.1(T.sub.TR), G.sub.2 (T.sub.WS)<0 only for T=T.sub.TRT.sub.WS>0. If the cycle is carried out in these temperature regions, it is driven entirely by thermal energy, i.e. a primary heat source. However, cyclically heating and cooling the oxide between T.sub.TR and T.sub.WS opens the possibility for thermal losses that may render H.sub.2 production inefficient in practice.
(23) At temperatures where reactions (1) and (2) are not spontaneous, additional energy must be provided to the system (generally in some form other than heat, i.e. a secondary energy source) in order to drive the reactions towards the same endpoints. The minimum amount of thermal energy, Q.sub.min that must be supplied to carry out the cycle in this general case is:
(24)
(25) The 1.sup.st term on the right-hand side is simply the reduction endotherm. The 2.sup.nd term accounts for thermal cycling, where C.sub.p is the molar specific heat capacity of the reactive oxide, F.sub.R is the molar fraction of the solid that is reactive (as opposed to inert), and .sub.R is the effectiveness of solid-solid heat recovery. The 3.sup.rd and 4.sup.th terms generically (the process is not specified) account for the scenario(s) where reactions (1) and/or (2) are carried out at unfavorable temperatures, i.e. when G.sub.1(T.sub.TR)>0 and/or G.sub.2(T.sub.WS)>0, and represent the minimum work must be performed to drive reaction (1) and/or (2). This work is determined by G.sub.1 and/or G.sub.2 at the respective conditions. Coefficients .sub.1 and .sub.2 account for losses in converting heat to the required amount of work. Additionally, they implicitly include the possibility that waste heat (i.e. heat of reoxidation and unrecovered oxide sensible heat) can be used to provide part of the work in the 3.sup.rd and 4.sup.th term. (See also discussion of eq. 11.) The limiting case (Q.sub.min=H.sub.1) applies to a system operating in the favorable temperature regimes with ideal heat recovery (.sub.R=1).
(26) To understand the implications of eq. 5, consider the situation where T=0 (ITWS), at a temperature intermediate to those of the thermodynamically favorable regimes. In this case, no energy is required for thermal cycling (the 2nd term is zero), but work must be added to both reactions (1) and (2). As T.sub.TR=T.sub.WS change in value, the 2nd term remains zero and G.sub.1 and G.sub.2 increase and decrease in opposition to one another. As discussed below, the thermodynamic limits of this special case can be determined without any knowledge of the reactor design or properties of the working materials.
(27) More interestingly, from an application perspective, if T.sub.TR is increased and T.sub.WS is decreased (TSWS), the thermal cycling energy requirement (2nd term) becomes nonzero and grows, but the work requirements embodied by G.sub.1 and G.sub.1 decrease and are eventually eliminated. Thus, eq. 5 suggests that for a given material (defining the thermodynamics) and set of reactor and process designs (defining the various efficiencies, practical and physical limitations, parasitic losses, etc.) there should be such T.sub.TR and T.sub.WS, that minimize the sum of the last three terms in eq. 5, and therefore Q.sub.min.
(28) Determining the conditions under which a two-step reactor operates at maximum efficiency requires the knowledge of the thermodynamic properties of the working material, as well as a reactor model. Specific thermodynamic properties of reactive oxides are not generally known, and are typically determined by extensive experimentation. Generalizations can therefore be made, but there is no universal solution.
(29) For the purpose of demonstrating efficiency calculations, we use assume CeO.sub.2 as the active oxide, a well characterized candidate material for solar thermochemical water splitting. The thermodynamics of CeO.sub.2 are obtained from the work of Zinkevich et al. (M. Zinkevich, D. Djurovic, F. Aldinger Thermodynamic Modelling of the Cerium-Oxygen System Solid State Ionics, 2006; 177, 989.). These authors performed a comprehensive, critical review of the thermodynamic literature concerning cerium oxides and applied a Calphad analysis to derive models covering all relevant phases (including both liquids and solids). This comprehensive approach covers the entire temperature range relevant to our analysis, and is necessary to accurately describe non-stoichiometric phases, such as the ceria fluorite phase (CeO.sub.2-) of concern here, which persists from =0 to 0.3 at 1773 K. This model also generally predicts lower values of (p,T) than models based solely on the experiments by Panlener (R. J. Panlener, R. N. Blumenthal, J. E. Gamier A Thermodynamic Study of Nonstoichiometric Cerium Dioxide Journal of Physics and Chemistry of Solids 1975, 36, 1213.), used in almost all previous studies. This difference leads to lower overall efficiency predictions for the comprehensive approach, but the conclusions of the analysis remain unchanged by the choice of model. The difference between ceria reduction models is illustrated in
(30)
(31) The reactor is assumed to accomplish four primary unit operations, common to many thermochemical reactor designs. These are a thermal reduction, solid-solid heat exchange in a thermal recuperator, H.sub.2 production (water splitting), and steam pre-heating. During operation, concentrated solar radiation heats and thermally reduces the reactive oxide in a thermal reduction chamber. The oxide then moves through the recuperator (entering at the hot inlet) and then into an H.sub.2 production chamber, where it is exposed to a pre-heated steam flow in a countercurrent arrangement, producing H.sub.2. The reoxidized material is then brought back to the reduction chamber, via the recuperator, where heat is exchanged between the two oxide flows.
(32) The reactor heat-to-H.sub.2 efficiency or reactor efficiency, .sub.R, is defined as:
(33)
where {dot over (n)}.sub.H.sub.
(34) The H.sub.2 molar production rate in eq. 6 can be expressed in terms of the heat input power ({dot over (Q)}.sub.TH) and the heat required for production of 1 mol H.sub.2 (Q.sub.mol):
(35)
(36) After losses to aperture intercept (A=0.95) and thermal re-radiation (P.sub.rad), {dot over (Q)}.sub.TH can be expressed as:
{dot over (Q)}.sub.TH=A*{dot over (Q)}.sub.AP.sub.rad(8),
whereas Q.sub.mol is:
Q.sub.mol=Q.sub.TR+Q.sub.SH+Q.sub.AUX(9)
(37) Here the individual terms (roughly ordered by decreasing temperature) correspond to those in eq. 5 as follows: Q.sub.TR=H.sub.r(CeO.sub.2) is the thermal reduction endotherm. The energy required for heating the oxide (sensible heat) from T.sub.WS to T.sub.TR (assuming F.sub.R=1) is:
(38)
where the molar heat capacity of CeO.sub.2 is C.sub.p80 J/mol K..sup.22 Finally, Q.sub.AUX encompasses the heat equivalents of other, auxiliary, energy requirements:
Q.sub.AUX(Q.sub.H.sub.
(39) Here Q.sub.H2O is the energy required to heat steam by T.sub.I/O=T.sub.WST.sub.0, i.e. from ambient temperature (T.sub.0) to T.sub.WS, and it includes preheating by hot product streams. The heat equivalents of the pumping of products (in both chambers) and mechanical and separation work are Q.sub.pump, Q.sub.mech, and Q.sub.sep, respectively. The negative terms represent the waste heat available from the product gasses, mainly the H.sub.2OH.sub.2 mix, which consists of the heat released at T.sub.WS in the reoxidation reaction, Q.sub.MOX=H.sub.rH.sub.cH2.sup.0, and the unrecovered sensible heat of the oxide, Q.sub.SH,L. Steam, in the fuel production chamber, acts as both a reactant (oxidizer) and a coolant. The sensible heat in the oxygen exhaust is Q.sub.O2.
(40) Importantly, Q.sub.AUX is forced to be non-negative, i.e. it is set to zero when the waste heat exceeds the first three terms in eq. 11, since heat at T.sub.WS cannot contribute to either Q.sub.TR or Q.sub.SH. The quantities in eq. 11 are heat equivalents, so conversion efficiency terms are included where applicable, such as the conversion of heat to mechanical or pump work. An efficiency of 10% was used for heat-to-pump work and for the oxide moving work. Thermal reduction and water splitting are assumed to end in their thermodynamic equilibrium states, i.e. kinetic limitations are not considered.
(41) The appeal of ITWS lies in the perceived simplification of reactor design and operation, as it eliminates the need for solid-solid heat recovery and, depending on the design, the frequent temperature cycling of reactor components. Coincidentally, this special case lends itself to straightforward theoretical analysis. To begin, we use well-known relationships for each of the reactions (1), (2), and (3):
G=RT ln K and G=HTS(12) and (13),
where R is the gas constant. The equilibrium constants for reactions (1) and (2) depend on the reactant and product activities:
(42)
(43) At all relevant operating pressures, the gas activities can be expressed as partial pressures:
(44)
where p.sub.O.sub.
(45)
(46) Here T.sub.iso, is the isothermal operating temperature. Solving for T.sub.iso is facilitated by the exact cancellation of the oxide terms on the left and right side of eq. 18, giving:
(47)
(48)
(49)
are assumed. These are the values at 1673 K and best represent the temperature range of practical interest. Adopting values for a different temperature introduces very small differences in the results. The fading rectangle in
(50)
(51) Referring again to
(52) It is important to understand that the results in
(53) Increasing T.sub.iso corresponds to less strict p.sub.O2 (higher) and n.sub.w/h (lower) requirements, and isothermal temperatures as high as 2173 K have been considered. However, radiation losses through the reactor aperture, as well as oxide sublimation and reactivity with reactor structures, limit T.sub.TR to no more (and possibly substantially less) than 1773 K in devices of practical relevance. To appreciate the challenge of ITWS under the extreme conditions considered in the literature, it is instructive to note that at 2173 K, ceria has a vapor pressure p.sub.CeO29.3 Pa, leading to a swift and irreversible oxide loss via sublimation, as observed experimentally by Abanades et al.
(54) It is assumed that low p.sub.O2 is achieved by pumping, i.e. lowering of p.sub.TR, the total pressure in this step (therefore p.sub.O2=p.sub.TR). As shown in a previous analysis, the heat equivalent of pump work is not a major contributor to the total energy requirement, but the lowest p.sub.TR is limited by other factors, such as oxygen volumetric flow and entering the molecular flow regime, to no less than 1 Pa.
(55) The alternative, isothermal inert gas sweeping, was examined by Bader et al., who showed that, even under best-case conditions, the amount of required N.sub.2 by far exceeds the amount of the H.sub.2 product (n.sub.N2/n.sub.H2700). In addition to requiring an N.sub.2 purification plant, the only manner of somewhat efficient ITWS was found to require exceptionally high levels of heat recovery (>95%) between the incoming and outgoing N.sub.2 gasat T.sub.iso. Finally, the vast majority of the products are the inert-oxygen mix and steam, not H.sub.2. It can thus be concluded that sweeping is not an option for ITWS.
(56) The above practical limitations regarding T.sub.TR and p.sub.TR give context to the results in
(57) For a deeper insight into the implications of the tradeoffs associated with ITWS, the low H.sub.2 fraction or high n.sub.w/h values can be viewed in the context of separation work, i.e. the work that must be performed to separate H.sub.2 from the H.sub.2-poor output stream. Separation work is directly related to efficiency, and practical ITWS efficiency limits, as defined in eq. 6, can be estimated by including some well-established efficiencies of the constituent processes. Re-radiation losses are given in eq. 8 (T.sub.iso.sup.4). Separation work (2.sup.nd law) depends on T.sub.iso, n.sub.h/w, and the final H.sub.2 purity, assumed here to be a modest x.sub.H2=99.9%. The practical separation efficiency (i.e. theoretical 2.sup.nd law work vs. actual work) is generally 15%, albeit not at the high temperatures considered here. The heat-to-power efficiency of a Rankine cycle in concentrated solar power plants, necessary to perform pump and separation work, is at best 40%. Finally, neglecting other work and heat requirements, and keeping the assumption for the heat-to-pumping efficiency (10%) from Section 2.2, plotted in
(58) The results show that the ITWS .sub.R values are low, even at high T.sub.iso and low p.sub.O2. The limits are almost independent of T.sub.iso and depend very weakly on p.sub.O2. In light of the outstanding operating conditions shown in
(59) The above results describe the conditions required for ITWS and indicate the practical difficulties in realizing it, including inherent limitations on efficiency. In this section, the effects of operational parameters on efficiency in the general case where T0 are examiner. In this case, both material and reactor assumptions, as discussed above are included. p.sub.TR is limited to values between 1 Pa and 1 kPalow enough to meaningfully facilitate thermal reduction, but not too low to be entirely unfeasible in a reactor in the field. Likewise, T.sub.TR 1773 K is set.
(60) The above results describe the conditions required for ITWS and indicate the practical difficulties in realizing it, including inherent limitations on efficiency. In the following paragraphs, the effects of operational parameters on efficiency in the general case where T0 are examined. In this case, both material and reactor assumptions as detailed above are included. p.sub.TR is limited to values between 1 Pa and 1 kPalow enough to meaningfully facilitate thermal reduction, but not too low to be entirely unfeasible in a reactor in the field. Likewise, we set T.sub.TR 1773 K.
(61)
(62) As can be seen in
(63) The latter is a special case of a more general result, also evident in
(64) T.sub.opt, defined as the value of T(p.sub.TR, .sub.R, .sub.GG) for which Q.sub.min (eq. 5) is the smallest, and efficiency (.sub.R) is the highest, can now be determined. To visually introduce the T.sub.opt concept, the efficiency curves in
(65) A peak efficiency, .sub.R(T.sub.opt), exists for any of the combinations of p.sub.TR, .sub.R, and .sub.GG in
(66) Some of the efficiency curves in
(67) The coinciding efficiencies in
(68) In light of this, the reasons behind the very low efficiency for ITWS are straightforward: While no energy is needed to heat the oxide after the water splitting reaction (Q.sub.SH=0 in
(69) Second, for T>T.sub.opt, oxide heating is the largest energy requirement and it requires direct solar input (to the extent that .sub.R<1). In this region, Q.sub.H2O is small, mainly because, at low T.sub.WS, comparatively little steam is needed to oxidize ceria back to equilibrium (n.sub.w/h is small), but also because T.sub.I/O is smaller, compared to ITWS. Therefore, Q.sub.SH/Q.sub.H2O>1. In fact, at T>T.sub.opt, Q.sub.AUX<0, necessitating heat rejection. Alternatively, this high quality waste heat can be used for other purposes, even though it cannot directly increase reactor efficiency. This corresponds to a small 4.sup.th right-hand term in eq. 5 (compared to the 2.sup.nd term).
(70) Lastly, coinciding efficiency curves for .sub.R=0 and .sub.R=0.75 reflect the particulars of ceria thermodynamics. As it happens, below T.sub.opt(p.sub.TR), decreasing p.sub.TR by a factor of 10 is equivalent, in efficiency terms, to increasing .sub.R from 0 to 0.75.
(71) The high .sub.GG required for efficient ITWS and low T operation warrants some further consideration. High levels of gas-gas heat recovery (>97%) are attainable at temperatures up to roughly 923 K using stainless steel recuperators. At higher temperatures, creep and corrosion limitations require the use of nickel alloys (up to 1273 K), and no recuperators operating at 1773 K or higher have been reported. Since in ITWS Q.sub.H2O is the highest, the role of gas-gas heat exchange is critical. For ITWS at p.sub.TR=1 Pa, T.sub.iso=1773 K and T.sub.I/O=1475 K, nearly 100 mol of steam must be heated per mole of produced H.sub.2 (
(72) The above further underscores the challenges associated with ITWS: If an exceptionally high .sub.GG cannot be achieved in practice, the efficiencies for ITWS would be even lower than those shown in
(73)
(74) The results in
(75) Solid-solid heat recovery being also challenging, we have consistently included the limiting case of .sub.R=0. Understanding that .sub.R=0.75 is near the upper end of what may be possible in practice, plots such as that in
(76) It should be noted at this point that the assumption that all reactions end in their thermodynamic equilibrium states is more important in ITWS, when is small and the system operates near equilibrium, than for T>0, when is comparatively large. Therefore, any deviations from this assumption, as is certain to be the case in practice, would further disfavor ITWS.
(77) In addition to maximizing efficiency for a given reactor/material system, knowing T.sub.opt can guide reactor design.
(78)
SUMMARY
(79) As seen in
(80) Further, in addition to posing extraordinary design and operational demands, ITWS offers no efficiency payoff. On the contrary, it appears to be the most inefficient fashion of producing H.sub.2 from H.sub.2O in a two-step cycle (
(81) Recalling that the question in solar fuel production is not one of feasibility, but of efficient solar utilization and minimization of the product cost, no ITWS advantages are evident in our analysis. Rather, requiring that T.sub.TR=T.sub.WS seems to be an unnecessary and counterproductive limitation. On the other hand, TSWS at T.sub.opt maximizes solar resource utilization, and the associated low steam requirement simplifies plant design and operation.
(82) The very existence of T.sub.opt may seem peculiar if one thinks of thermochemical reactors as engines that reverse combustion, i.e. where heat is the input and fuel (chemical work) is the output. It may initially appear most plausible that maximizing T would also maximize efficiency. In the case of perfect heat recovery (.sub.R=.sub.GG=1), this would be correct. It is because of the reality of non-ideal heat recovery that T.sub.opt exists at all.
(83) Some general implications regarding reactor operation follow from the above results. Under all conditions, the slopes of the efficiency curves are shallower for T>T.sub.opt than for T<T.sub.opt. Furthermore, the reasons for suboptimal efficiency are different in these two regions. For T>T.sub.opt, the oxide heating requirement results in the production of high quality waste heat (at T.sub.WS), which can be used elsewhere in the plant, even if not for H.sub.2 production directly. For T<T.sub.opt, however, efficiency decreases because of the steam heating requirement, with waste heat available at low temperature (following steam-steam heat recovery) and of little value. This suggests that it may be prudent to err on the side of T>T.sub.opt, rather than the opposite, in order to achieve higher average efficiency under the variable environmental conditions present in practice. Even though the feasibility of thermochemical fuel production using ceria as a working oxide has been demonstrated, a consensus exists regarding the need for material improvements. Most notable of them is the need for a material that provides a higher at a higher p.sub.TR and lower T.sub.TR than, for example, ceria, yet with similar kinetics and stability. In addition to the possibility of less demanding operation (at a lower required T.sub.TR), a higher would enable higher yields, so that less oxide must be heated per unit produced H.sub.2 or fuel in general. Importantly, this increase must not be offset by an equal increase in C.sub.p or more precisely C.sub.pT (cf. eq. 10 and compare, for example, C.sub.p for ceria with that of LaMnO.sub.3 or La.sub.1-xSr.sub.xMnO.sub.3). A material that reduces more easily than ceria (larger under identical T.sub.TR and p.sub.TR) will generally also be more difficult to reoxidize, assuming similar and temperature independent values for S. This assumption is justified as S is largely a function of the evolution of oxygen into the gas phase. Operationally, this suggests that advanced materials may require a lower T.sub.WS (larger T) for reoxidation to achieve the same n.sub.w/h2. In other words, an insufficiently large /C.sub.p increase could be offset by an increase in the 2.sup.nd right-hand term in eq. 5, and therefore decrease efficiency.
(84) Understanding this, it is to be expected that optimal operation with advanced materials is likely to involve an increase of T.sub.opt, not its decrease in the direction of ITWS. Precise details would additionally depend on reactor design and various internal efficiencies such as .sub.R, .sub.GG, etc. This also follows from general thermodynamic consideration regarding the maximum theoretical efficiency of a two-step thermochemical process. Because of strict thermodynamic limitations, ITWS is unlikely to benefit from the use of advanced materials.
(85) While some key design and operating parameters of a thermochemical reactor for two-step H.sub.2 production present obvious tradeoffs between difficulty and efficiency, T is not one of them. For example, the higher the degree of heat recovery (.sub.R or .sub.GG), which is increasingly difficult to accomplish, the higher the efficiency. One must therefore find a balance that minimizes the levelized cost of the H.sub.2 product. The choice of T is easier to make: operating difficulty being largely independent of T, it would always be advantageous to operate at T for which efficiency is the highest.
(86) Finally, it should be noted that even though much of this analysis is specific to CeO.sub.2 as a reactive oxide, it can be applied to any material for which sufficient thermodynamic information is available. With appropriate small adaptations (mainly heat capacity and dissociation coefficients), the analysis can also be applied to the solar-thermochemical production of CO from CO.sub.2, with largely the same conclusions.
(87) Lastly, the conditions (T.sub.iso, p.sub.O2 and n.sub.w/h) required for isothermal two-step thermochemical water splitting (T.sub.TR=T.sub.WS) can be determined based on water thermodynamics and are highly mutually dependent: choosing values for any two defines the third. This analysis shows that isothermal water splitting is impractical, being a choice between high thermal reduction temperatures, very low oxygen partial pressures for thermal reduction, or exceptionally high steam requirements (i.e. high separation work)or some combination of the three.
(88) Isothermal water splitting is substantially less efficient than the same process at T>0. This is true even in the complete absence of solid-solid heat recovery in the latter case, and assuming a high steam heat recovery effectiveness at high temperature. The low efficiency of ITWS is primarily a result of the exceptionally high energy requirement for steam heating in the water splitting step of the cycle.
(89) Given a specific reactor/material combination, an optimal T=T.sub.TRT.sub.WS can be found to maximize efficiency. For reasonable values of process parameters in a ceria-based cycle, this T.sub.opt ranges roughly between 250 K and 400 K, and is expected to increase in well-designed advanced materials.
(90) A combination of pressure and temperature swing, rather than either individually, is by a wide margin the most efficient mode of operation of a two-step cycle thermochemical reactor for hydrogen production. Efficiency being of paramount importance for the practical application of this technology, temperature and pressure swing reactors appear to be the most promising direction for future research and development.
(91)
(92) As so described, the artisan will appreciate that with many independent design parameters, a design protocol for the reactors described herein may include first determining thermal reduction properties of the reactive particles (e.g., reaction kinetics at a chosen reduction temperature and oxygen partial pressure). A solar concentrator power, overall particle mass flow rate through the reduction chamber, and feed stock pumping speed may be independently set to establish the desired reduction temperature, pressure, and residence time within the reactor. Similarly, the production temperature, and production residence time may be set by appropriate component sizing and adjusting the flow of the reactant fluid (two more independent parameters).
(93) It is to be understood that the above description is illustrative, and not restrictive. For example, while flow diagrams in the figures show a particular order of operations performed by certain embodiments of the invention, it should be understood that such order is not required (e.g., alternative embodiments may perform the operations in a different order, combine certain operations, overlap certain operations, etc.). Furthermore, many other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. Although the present invention has been described with reference to specific exemplary embodiments, it will be recognized that the invention is not limited to the embodiments described, but can be practiced with modification and alteration within the spirit and scope of the appended claims. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.