DrFaizanAhmadSeniorLecturerinChemicalEngineering

SchoolofScienceandEngineeringTeessideUniversity,UnitedKingdom

Chemical Engineering Post Doc Yeungnam University, South Korea (2014-15) PhD Univeriti Teknologi Peronas, Malaysia (2009-13) MS Otto-von Guricke University, Magdeburg, Germany (2004-07) BSc (Engg) University of the Punjab, Pakistan (2000-04)

Track Record Over 20 peer-reviewed journal articles, over 15 conference contributions, 1 Patent filed, 2 Gold medals and1 silver medal in innovation exhibitions Research Interests Carbon capture Environment and Energy Membrane Technology Process Modelling and Simulation

AcademicBackground

Alignment of My Research Area and Workshop Topic

WasteManagement/

ResourceEfficiency

LowCarbonEconomy

CO2canberesourceratherthanwaste

How CO2 Can be Resource

Ref:CarbonDioxideCanBeAResourceRatherThanAWasteProduct,TheEnergyCollecNve,Feb.2014

MoAvaAon for Carbon Capture Technology

ClimateChange

Source:PeNtet.al.,Nature,2000

Coal76%

NG14%

Fueloil9%

Other1% H2

Power79%

NGSweet

Refineries6%

Cement7%

Steel5%

Petro.Chem.3%

MoAvaAon for CCS Technology Energy Profile

GlobalCarbonDioxideEmissionsfromPowerGenerationperyearTotal=10,539Mt

GlobalCO2EmissionsperyearTotal=13,375Mt

(60%oftotal)

Carbon Capture OpAons Technologies Overview

¡  Systems§  Pre-combusNon§  Post-combusNon§  Oxy-fuelcombusNon

¡  SeparaNontechnologies§  Solvents–aqueousaminesandsalts§  Membranes–polymeric§  Solidsorbents–zeolite,acNvatedcarbon§  Cryogenicprocesses§  ChemicalLooping(Calciumlooping)

Advantages of Membrane SeparaAon

HighEfficiency LowEnergyRequirements

EaseofOperaNon

MechanicallyRobust

LowCapitalandOperaNng

Cost

EnvironmentalFriendly

Projected Growth in Membrane Market Demand (USD)

220Million(2020)

90Million(2010)

30Million(2002)

Reference:

R.W.Baker,"FutureDirecNonsofMembraneGasSeparaNonTechnology," Industrial&EngineeringChemistryResearch,vol.41,pp.1393-1411,2002.

ClassificaAon and SelecAon of Membrane Module Tubular

Module Plate and Frame Module

Spiral Wound Module

Capillary Module

Hollow Fiber Module

Manufacturing cost (USD/m2)

50-200 100-300 30-100 20-100 5-20

Packing density(m2/m3)

Low Low Moderate Moderate High

Resistance to Fouling

Very good Good Moderate Good Poor

Parasitic pressure drops

Low Moderate Moderate Moderate High

Suitable for High pressure operation

Can be done with difficulty

Can be done with difficulty

Yes No Yes

Limitations to Specific Type of Membranes

No No No Yes Yes

Hollow Fiber Membrane Module

•  Hollowfibermembranemoduleisemployedbymorethan80percentgasseparaNonfaciliNesinindustry

•  CosteffecNveandHighestpackingdensityincomparisontoothermodules.

•  Extremelyfinepolymerictubeshavingdiameterof50-200micron

•  Hollowfibermembranemodulewillnormallycontaintensofthousandsofparallelfiberspocedatbothendsinepoxytubesheets

Ref: J. P. Montaya., Membrane Gas Exchange. 2010, Available: http://permselect.com/files/Using_Membranes_for_Gas_Exchange.pdf

Membrane Module Development

MembraneProperNes:Polyimide(Matrimid)Innerdiameteroffibers:250µm

Outerdiameteroffibers:400µmLengthoffibers:28cmNumberoffibers:5,15,20,30,50

Flow sheet of Gas PermeaAon TesAng Unit

Natural gas CH4 CO2 N2

Feed Vessel

Hollow Fiber Membrane Module

Static mixer

F

Flow meter

T

Thermocouple

P

Pressure guage

F

TPBackpressure

Regulator

Pressure guage Thermocouple

F

Flow meter

Flow meter

P T

Pressure guage Thermocouple

Infrared Analyzer

Flow controller

Data Acquisition System (Computer)

Compressor

Oven

Gas PermeaAon TesAng Unit (CO2 from Natural Gas)

Example of Research Findings (Effect of Module CharacterisAcs on Gas Processing Cost)

0,01

0,02

0,03

0,04

0,05

0,06

0,07

0,08

0,09

0,1

0 100 200 300 400 500

GPC

(USD

/MSCFofprodu

ct)

Lengthoffibers(cm)

LowerconcentraNonfeed(10%CO2)

MediumconcentraNonfeed(40%CO2)

0,01

0,02

0,03

0,04

0,05

0,06

0,07

0,08

0,09

0,1

0 5 10 15 20 25 30 35

GPC

(USD

/MSCFofprodu

ct)

Radiusoffiberbundle(cm)

LowerconcentraNonfeed(10%CO2)MediumconcentraNonfeed(40%CO2)HighconcentraNonfeed(70%Co2)

0

0,01

0,02

0,03

0,04

0,05

0,06

40 45 50 55 60 65

GPC

(USD

/MSCFofprodu

ct)

Porosity(%)

LowerfeedconcentraNon(10%CO2)MediumfeedconcentraNon(40%CO2)HigherfeedconcentraNon(70%CO2)

0

0,01

0,02

0,03

0,04

0,05

0,06

0,07

0,08

0,09

0 0,005 0,01 0,015 0,02 0,025 0,03

GPC

(USD

/MSCFofprodu

ct)

Outerdiameteroffiber(cm)

LowerfeedconcentraNon(10%CO2)

MediumfeedconcentraNon(40%CO2)

Comparison of Process Performance and Economics

0

0,005

0,01

0,015

0,02

0,025

0,03

0,035

0,04

0,045

95,5

96

96,5

97

97,5

98

98,5

99

99,5

0 5 10 15 20 25 30 35

GPC

(USD

/MSCFofprodu

ct)

Metha

nepurity

(%)

Radiusoffiberbundle(cm)

MethanePurity(%)

GPC(USD/MSCFofproduct)

Hybrid Membrane Processes

Hybridmembrane/disNllaNonprocess

Hybridmembrane/cryogenicprocess

Hybridmembrane/absorpNonprocess

Current Project: Process IntensificaAon Hydrogen on Teesside/North East England

•  BACKGROUND

TheNorthEastisaworldleaderinthelargescalemanufactureofhydrogen,producingmorethan50%oftheUK'stotalinTeesValley.ArecentstudyoutlinesopportuniNestoincreasethisfurtherreaffirmingtheregion'sposiNonasthethirdlargesthydrogeneconomybehindLondonandAberdeen.

Tees Valley and North East Hydrogen Economic Study Final Report 16thOctober2014

GlobalTrends(fromWorldHealthOrganizaTon)-  TheglobalurbanpopulaNonisexpectedtogrowbyapproximately1.7%peryearbetween2015and2030.-  Currently>80%ofpeoplelivinginurbanareasthatmonitorairpolluNonareexposedtoairqualitylevels

thatexceedWHOlimits.-  Accordingtothelatesturbanairqualitydatabase,98%ofciNesinlow-andmiddleincomecountrieswithmorethan100000inhabitantsdonotmeetWHOairqualityguidelines.

Making Hydrogen on Teesside

Hydrocarbon Feed

Steam

Shift Conversion

Steam Reforming

Sulphur Removal

PSAUnit

Product Hydrogen

Purge Gas to Steam Reformer Burners CnHm+nH2O=>nCO+((n+m)/2)H2

CH4+H2O<=>CO+3H2CO+H2O<=>CO2+H2

Althoughhydrogenfromnaturalgasiscertainlyaviablenear-termopNon,itisnotviewedbyDOEasalong-termsoluNonbecauseitdoesnothelpsolvethegreenhousegas(GHG)orenergysecurityissues.BUT……………………………………..ChickenandEgg,InvestorandConsumer

What is Process IntensificaAon

•  LowerCost(CAPEX–OPEX)•  Smallersize• HigherEfficiency•  SaferDesign• Becershape• Combinedprocesscomponents•  Sustainabledevelopment

AimsandobjecTves:i.  Standalone(orhybrid)andsmallscale

(suitablefor1-5kWFuelCellapplicaNonsforsmallresidenNalheaNng)

ii.  Demonstrated/ValidatedforoperaNonundersimulatedenvironments–uptoTRL5(TechnologyReadinessLevels)

iii.  ProjectedCosteffecNvenesstobesuperiortoconvenNonalPressureSwingAdsorpNon

(Ref:"TechnologyReadinessAssessment(TRA)Guidance";UnitedStatesDepartmentofDefense.April2011.)

CurrentProject:TodevelopaninnovaTveHydrogenpurificaTontechnologybasedonmembranesystems,withthefollowingaimsandobjecTves–

ForExample:

IncorporaNngtheuseofMembranereactor/separatortechnology(source:PallCorporaNon)toproducepureHydrogenfromaconvenNonalNaturalGasReformaNonsetup

ReplacingtheWatergasShirreactorwithaWGSmembranereactortocombinereacNonandseparaNon/purificaNonofhydrogeninonemoduleitself–onestageofprocessintensificaNon

IncorporaNonofMembranereactoratthereformingstageitselftoinducemoreWGSduringthereformaNonitself,andyieldpureH2–ulNmateprocessintensificaNon

Making and using Hydrogen is happening

Making and using Hydrogen is happening

•  BOCLindeinpartnershipwithDaimlertobuild13newhydrogenfuellingstaNonsinGermanybytheendof2015,tobesuppliedwithsustainablysourcedhydrogen.

•  HeadofCleanEnergy&InnovaNonManagementatLinde.“WearemakingavaluablecontribuNontothesuccessfulcommercialisaNonoffuel-cellvehicleswhilesupporNnginiNaNvesliketheCleanEnergyPartnership(CEP)and‘H2Mobility’.”“ThereisnoquesNonthatfuel-celltechnologyisreachingmaturity.From2017,weareplanningtobringcompeNNvelypricedfuel-cellvehiclestomarket.SonowistheNmetobuildanaNonwidefuellinginfrastructure.TheaimistoenablemotoriststoreachanydesNnaNoninGermanyintheirhydrogenfuelledvehicles.ThisiniNaNveisahugestepforwardonthejourneytoatrulynaNonwideH2network,”statesProfessorHerbertKohler,VicePresidentGroupResearch&SustainabilityandChiefEnvironmentalOfficeratDaimlerAG.

Making and using Hydrogen is happening

Blending hydrogen into natural gas pipeline networks has also been proposed as a means of delivering pure hydrogen to markets, using separation and purification technologies downstream to extract hydrogen from the natural gas blend close to the point of end use. As a hydrogen delivery method, blending can defray the cost of building dedicated hydrogen pipelines or other costly delivery infrastructure during the early market development phase.

What is Process IntensificaAon

•  LowerCost(CAPEX–OPEX)•  Smallersize• HigherEfficiency•  SaferDesign• Becershape• Combinedprocesscomponents•  Sustainabledevelopment

AimsandobjecTves:i.  Standalone(orhybrid)andsmallscale

(suitablefor1-5kWFuelCellapplicaNonsforsmallresidenNalheaNng)

ii.  Demonstrated/ValidatedforoperaNonundersimulatedenvironments–uptoTRL5(TechnologyReadinessLevels)

iii.  ProjectedCosteffecNvenesstobesuperiortoconvenNonalPressureSwingAdsorpNon

(Ref:"TechnologyReadinessAssessment(TRA)Guidance";UnitedStatesDepartmentofDefense.April2011.)

CurrentProject:TodevelopaninnovaTveHydrogenpurificaTontechnologybasedonmembranesystems,withthefollowingaimsandobjecTves–

ForExample:

IncorporaNngtheuseofMembranereactor/separatortechnology(source:PallCorporaNon)toproducepureHydrogenfromaconvenNonalNaturalGasReformaNonsetup

ReplacingtheWatergasShirreactorwithaWGSmembranereactortocombinereacNonandseparaNon/purificaNonofhydrogeninonemoduleitself–onestageofprocessintensificaNon

IncorporaNonofMembranereactoratthereformingstageitselftoinducemoreWGSduringthereformaNonitself,andyieldpureH2–ulNmateprocessintensificaNon

•  UsingtheconceptofProcessIntensificaNonforproducNonofHydrogen,i.e.,mulN-funcNonalreacNonseparaNonsystems,tolowercapitalcosts;

•  IntroducecomplexityandmulN-funcNonalityinthereactor–itismuchmoreeffecNvetodosoinsmallerscale,andhencetheapplicabilitytosmallersystems

•  IntegratedmaterialsprocessingandcharacterizaNon,reactordesignandtesNng,moduleandprocessdesign

Approachtotheproblem

ImpureHydrogenorHydrogencontainingfeedstock,obtainedbyusingsmallscaleprocesses

Process ComposiTonoffeedstock OpTonsforHydrogenpurificaTonbyuseofmembranes

AnaerobicfermentaNonofBiomass

50-85%Methane;20-35%CO2;H2,O2,N2andH2Sinvaryingamounts,uptoafewpercent

1.  Sulphurremoval(fromH2S)2.  ReformaNonofMethanetosyngas3.  WaterGasShir/HydrogenSeparaNon-

concentraNon

Hydrogenfrompipelines,caverns

Over99%Hydrogen,parNcles,dust,soils,S-odorant

OnlyMembraneassistedpurificaNon

Ref: Alberta Gas Ethylene Co. (AGEC) hydrogen pipeline (3.7 km in length) – The line currently carries 4,825 kg-mole/hr of 99.99% pure hydrogen at a maximum operating pressure of 5,790 kPa (57 bar) from the AGEC hydrogen purification plant to the Cominco Fertilizers/Alberta Energy Co. Ltd. plant.

Note:BydevelopingaprocessforgeneraLnghighpurityhydrogenfrombiomass,weareaddressingamorecomplexsystem;allotherpurificaLonmodulescanbesubsetsofthelargerproject

WorkBreakdownStructure(Workpackages)

1.ProcessConfiguraNon,ProcessDesignCalculaNonsforcomponentdesign

2.LaboratoryScaledevelopmentof‘selected’MembraneSystems

3.MeasurementofMembranePerformance

1.1IdenNfyarepresentaNveBiomassanaerobicdigesNonsystemassupplierforbiogas,toascertainexpectedcomposiNons,andimpurityconcentraNons;alsoidenNfyothersourcesofHydrogenlocally,whichrequirepurificaNonandarefeedstocksforPEMFCs–TU,withotherpartners1.2ProcessDesign–PFD,Mass-EnergyBalances,P&ID,anddetaileddesignofreactors,andpurificaNonsystems-TU1.3FabricaNonofmembrane-moduleassembly–Partners,Industry

2.1MembranesynthesistogenerateopNmalmorphology–TU,OtherUniversiNes/Labs(collaboraNve)2.2BasiccharacterizaNon–XRD,Surfacearea,microstructure(TU,OtherUniversiNes/Labs(collaboraNve)2.2Designofsuitable‘module’,andmembrane-moduleintegraNon(TU)

3.1PermeabilityexperimentsonsinglemembraneswithfocusonachievingselecNveexclusion/adsorpNonofCO2andotherimpuriNes,inbiogaswithhighthroughputofH2,closeto100%perm-selecNvity(TU)3.2.Membrane-ModuleTesNng(TUandPartners)3.3DegradaNonstudies,andmiNgaNonofflawsandimperfecNonsinthemembrane,membrane-moduleassembly(TUandPartners)

Reasonablelimitsforpressure–balancebetweenpermeabilityandpressure Reasonablelimitsforpermeabilitybasedon

pressuresensiNvity(above)–balancebetweenpermeabilityandmembranearea

PerformanceTargets•  99.99%hydrogenpurity•  90%recoveryofHydrogenfromfeed•  FeedcomposiNonstobe>50%Hydrogen

MembraneModulea\ributes,baseduponcalculaTonsPermeability–1500GPUPressure–10-15barAreas–0.06to0.10m2

ProcessCalculaTonsfor50%Hydrogenfeed,5kg/day–esTmaTonofpermeability,area,andpressurerequirements

BaseduponsimilarcalculaNons,MembraneModuleacributescanbeprojected,andsuchnumberscanbeachievedbymaterialsandmoduledesignopNmizaNon

Research Areas for Partnership • PurificaNonofHydrogenusingmembraneforfuelcellapplicaNon(Cleanenergy)

• PurificaNonofbiogasasrenewableenergysourceusinghollowfibremembraneprocess

• HybridMembrane-AbsorpNonprocessforCO2Capture