Electric synthetic fuels on their way to industrialisation - AVL
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Electric synthetic fuels
on their way to
industrialisation
21.02.2018 Christian Olshausen, Carl Berninghausen, Nils Aldag
Sebastian Becker, Karl Hauptmeier
Investors
22.02.2018 2
Company Facts
Knowhow
• 90 Employees
• Skills in Ceramics, Stack + System Production, Engineering, Synthesis Processes, etc.
Investors
Patents
• 43 patent families (i.e. »process patent sunfire« WO/2008/014854)
Recognition
• Cleantech 100 Company 2014/2015/2017/2018 (only fuel cell + electrolysis company)
• Fast Company Most Innovative Company of 2016 (with Tesla and Toyota)
• German Gas Industry’s 2016 Innovation & Climate Protection Award
• Kanthal Award 2017 for solutions in Sustainability, Quality of Life and Energy Efficiency
Revenues
• Multi-million Euro Revenues in Global Markets since 2011
Sunfire Technology
22.02.2018 4
Solid Oxide Cells Convert…
… electricity into hydrogen / syngas … fuels and gases into electricity and heat
Fuel Oxygen
Heat Electricity (-CH2-) (O2)
CO2
Steam &
(+CO2) H 2O
Hydrogen Oxygen Heat Electricity
(+CO) (O2)
Electrolysis Mode Power & Heat Mode
22.02.2018 5
Three Core USPs
Highest efficiency in hydrogen production
(82 %LHV or 3.7 kWh/Nm3) and power & heat
production (35 - 60 %AC and 90 %total) compared
to legacy technologies such as PEM and Alkaline
Tolerance to carbon in electrolysis mode via
co-electrolysis of CO2 and H2O and in fuel cell
mode via internal reforming of hydrocarbons Stack production in Dresden
(natural gas, LPG, diesel, etc.)
Flexible adjustment of output from part load to
full load (30 % - 120 %) in a short timeframe
Sunfire promises low costs, high reliability and
readiness to scale.
System testing in Dresden
22.02.2018 6
One Core - Multiple Products
PowerCore Sunfire-Remote
• Reliable power generation in remote sites
• 5 kW ∙ X
Sunfire-HyLink
• Efficient hydrogen production
• 185 kW ∙ X
Established
Sunfire-SynLink
SOC concept • Efficient syngas production
• 185 kW ∙ X
Multiple Applications
22.02.2018 7
e-Crude Production Pathways
Stage 1: electrochemical H2 production through Sunfire-HyLink system, followed by
reverse water gas shift conversion (RWGS)
Fischer-
Tropsch
Sunfire-HyLink
Sunfire-SynLink
Stage 2: electrochemical syngas production through Sunfire-SynLink system
• 2 step process through direct syngas production (no RWGS reactor needed)
• High electricity-to-fuel efficiency (~ 60 %LHV)
• Reduced OPEX and CAPEX
22.02.2018 8
Sunfire SOC Operation
Test Stack (30 Cells 3YSZ / 5YbSZ + LSCF)
20 x On/Off in 1ms from 0 to 80% Power Input: No Degradation
Cursor-analysis 1400 880
860
S/N: 3658 840
Art.-No.: - 1300
820
Type: SEC-B215-0ZZ-030
Test stand: 3.1 (FC3) 800
Temperature [°C]
Editor: C. Greß 1200 780
Power [W]
Created: 26.01.2015 760
1100 740
Operation time on load 720
V_air_act
V_H2_act 700
1000
V_N2_act 680
V_H2O_g
I_act 660
I_Netzteil_ist 900 640
P_act
P_Stack_calc 620
T_Kat_I_Tube 800 600
T_Kat_I_L15
T_MEA_1/2_L15 200 28
T_MEA_3/4_L14
T_MEA_4/4_L16 24
V_H2O(g) [Nl/min]
T_Kat_O_L15
V_air [Nl/min]
150 20
T_Kat_O_Tube
T_An_I_Tube
16
T_An_O_Tube 100
U_act 12
U_Stack_calc
Block 1 50 8
Block 2
4
Block 3
Block 4 0 0
Block 5
Block 6
Block 7 100 5.5
Block 8 90 5.0
Block 9 80
Block 10 4.5
Voltage [V]
Current [A]
70
60 4.0
50 3.5
40 3.0
30
2.5
20
10 2.0
0 1.5
1600 1610 1620 1630 1640 1650 1660 1670 1680 1690 1700 1710 1720 1730 1740 1750 1760 1770
Operation time [h]
22.02.2018 9
Sunfire SOC Operation
Test Stack (20 Cells 3YSZ + LSCF)
26 rSOC-Cycles: Linear Voltage Degradation 0,06 %/Cycle
23 Thermocycles: no cell defects
1200 880
Übersicht
860
t > 600°C: 1761 h 1000 840
t(SOFC) > 5A: 940 h 820
T_MEA_4/4_E16 [°C]
t(SOEC) > 5A: 346 h
800 800
Leistung [W]
780
Versuchsinfo:
rSOC 600 760
Zyklen 740
400 720
700
Sr.-Nr.: 3426
Art.-Nr.: - 200 680
Typ: SEC-B215-0ZZ-020 660
Zellfläche: 127 cm²
Teststand: 3.1 (FC3) 0 640
Bearbeiter: R. Stäber
300 60
erstellt: 16.10.2014
V_Luft [Nl/min]
250 50
V_BG [Nl/min]
V_Lu_ist 200 40
V_H2_ist 150 30
V_N2_ist 100 20
V_H2O(g)_ist
U_Stack_calc 50 10
I_Last_ist 0 0
I_Netzteil_ist
70 55
P_Stack_calc 50
60
Stromstärke [A]
T_Kat_E_Rohr 45
Spannung [V]
T_Kat_E_E10 50 40
35
T_Kat_A_E10 40 30
T_Kat_A_E10 30 25
T_Kat_A_Rohr 20
20 15
T_An_E_Rohr 10 10
T_An_A_Rohr 5
0 0
T_MEA_0/4_E14
T_MEA_1/2_E15 DP1 DP5 DP29
T_MEA_3/4_E04 SOFC-KL
Export ist noch Keine Datenaufzeichnung
T_MEA_4/4_E16 TZ Beginn TZ
FU=75%ausstehend wegen Ausfall PC
Ausfall MV_Purgegas
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Betriebsdauer [h]
22.02.2018 10
BOP: 88 %
Co-Electrolysis Fischer-Tropsch
85 % 81 %
Single Step Efficiencies Overall efficiency:
0,85 * 0,81 * 0,88 => 55 – 61 % (LHV/kWhel)
Sunfire produces Fischer Tropsch synthetic
fuel, which needs to be processed in
refineriesSector Coupling Focus: PtX
22.02.2018 12
Existing Value Chain for Oil and Gas
Large assets already in place using fossil natural gas and crude oil as feedstock
Economically feasible industrial decarbonisation in industrialized countries necessary
Otherwise industry will move to regions with less environmental protection
Processing
Fossil Inputs End-products
Refinery &
(Upstream) Chemicals (Downstream)
Examples
Diesel
Gasoline
Jet-A
Hydrogen Ethylene
Refinery Product 1
Nat. Gas Plastics
Petro-chemistry Product 2
Syngas Foils
Specialty Product 3 Foam
Crude Oil Chemicals … Solvents
Cosmetics
Pharmaceuticals
…22.02.2018 13
Sector Coupling with Sunfire Using the Existing Value Chain
Sunfire makes use of existing assets instead of changing all processes and
infrastructures individually (no disinvest – no stranded assets)
Renewable/ CO2-neutral property is sold with e-Fuel certificates to any possible
customer, similar to renewable energy in the electricity grid Open-Grid-Concept
Processing
Renewable Inputs End-products
Refinery &
(Upstream) Chemicals (Downstream)
ren. energy certificates e-Fuel certificates
Examples
Diesel
Gasoline
Jet-A
HyLink e-Hydrogen Ethylene
Refinery Product 1
Plastics
Petro-chemistry Product 2
SynLink e-Syngas Foils
Specialty Product 3 Foam
SynLink+ e-Crude Chemicals … Solvents
Cosmetics
Pharmaceuticals
…C–H-O A general approach
22.02.2018 15
C–H-O
H H2O (water)
O
H2-economy
H2O + CO2
(combustion
products)
CH2O (Biomass)
-CH2-
H H (Petrol, CO2 (Carbon Dioxide)
H C C Diesel, Wax)
H H High
enthalpy
C1 = methane
C2 = ethane
C3 = propane
C4 = butane
C5 – C10 = benzene C6H2O
(coal)
C11 – C20 = diesel
C9 – C16 =kerosene
= Combustion
>C20 = wax C
= Photosynthesis
= Oiling
= Coalification
Source: Dissertation Dr. B.M. Wolf, 197622.02.2018 16
Sugar, flour,
C–H-O Nivea spaghetti
H2O (water)
H O
Natural
gas
Olive oil
CH2
(Petrol, CO2 (Carbon
Diesel, Wax) Dioxide)
Alcohol
Wood
C
FlavoringsPower-to-Liquids Current Status and Next Steps
22.02.2018 18
Sunfire BMBF Project
Steam Electrolysis
Capacity: 5 – 10 kW
Start up: As of Q4/2014
Fuel 1 test plant for RWGS & Fischer-Tropsch
Capacity 1 bbl/day (159 Liters)
Start up As of Q4/201422.02.2018 19 Sunfire BMBF Project Opening Ceremony on November 14th, 2014
22.02.2018 20 Sunfire BMBF Project German Federal Minister of Education and Research receives the first liters / Car manufacturer Audi confirms the fuel’s eco- friendliness!
22.02.2018 21
Sunfire e-crude properties
Aromate content < 1 wt.-%, no sulphur cleaner combustion (no particles)
High proportion of n-alcanes good ingnition quality (cetane no.)
CHARACTERISTICS DIESEL (EN590) SUNFIRE FIRST DISTILLATE
GRAVIMETRIC DENSITY 820 … 840 kg/m³ 780 kg/m³
LHV 42,5 MJ/kg 44,71 MJ/kg
ENERGY DENSITY 34,9 … 35,7 MJ/L 34,9 MJ/L
CETANE NUMBER > 51 65 … 76
*Preliminary Analysis from Petrolab/Speyer => Drop in for refineries22.02.2018 22
Sunfire e-Crude production with Nordic Blue Crude
Stage 2 for e-Kerosine, e-Diesel and e-Wax
Start of operation: ca. 2021
Sunfire-SynLink+ Capacity: ca. 8,000 t/a e-Crude
21,000 tonnes/a of CO2 mitigation
Electricity-to-fuel efficiency of ca. 60 %LHV22.02.2018 23
e-Fuels Predicted to Play Large Role in the Future
18000 18000
16000 16000
ca. 10,300 PJ 14000
ca. 10,300 PJ
14000
12000 12000
10000 10000
8000 8000
6000 6000
4000 4000
2000 2000
0 0
2020 2030 2040 2050 2020 2030 2040 2050
Passenger Vehicles Buses Rail (passenger) Rail (freight) Trucks Ships (freight) Aviation Fossil Fuels Electricity H2 Methane eFuels
Calculation based on dena/LBST „E-Fuels –The potential of electricity based fuels for low emission transport in the EU”, 2017
In 2050, hard-to-electrify sector will make up 50 % or 5,000 PJ
For e-Fuels to be available in those quantities after 2030, we must start now22.02.2018 24
Value Chain Chemical Industry
DREAM Fuel (X):
Electricity:
Power-to-X-Plant + 5 €ct/kWh
+ 50 €ct/ Liter
5 €ct/kWh + 79,50 € /barrel
CAPEX: 0 In practice: X 2-3!
100 % Efficiency22.02.2018 25
Value Chain Chemical Industry
Fossil & Renewable Value Chains in Comparison
Energy Collection Energy Processing Conditioning Distribution
Photo-
Chlorophyll Refinery Distribution
synthesis Cost
Parity /
Merit
Order
Wind mill/
Power-to-X Refinery Distribution
Solar Power Plant
Fossil Resources Explo-
Refinery Distribution
“Free Lunch” ration
+ Not closable via R&D (first law of thermodynamics)
+ Cost externalisation via CO2 - emission22.02.2018 26
Solar Fuel Production
Energy Collection Energy Processing Conditioning Distribution
Solar Power Plant Refinery Distribution
One material for electron
activation + molecule
reduction leads to material
compromiseEmission & LCA
22.02.2018 28
Particles and NOx
0,35 ΔNOx = - 37%
0,30 ΔNOx = - 21%
emissions [g/km]
ΔPM = - 26% ΔPM = - 24%
0,25
0,20 NOx
0,15 PMx10
0,10
0,05
0,00
Diesel Fuel 4 Fuel 4 NOxmin Pmmin
Pump
Source: Renew, Engelbert, Choren22.02.2018 29
Particles and NOx
0,035
0,030
EU IV limits
reference Diesel
0,025
particle [g/km]
0,020
Fuel 4
0,015
Kerosine high
0,010
0,005
0,000
0,000 0,050 0,100 0,150 0,200 0,250 0,300 0,350
Source: Renew, Engelbert, Choren NOx [g/km]22.02.2018 30 LCA - GHG
THANK YOU!
Upon request, further presentation sunfire GmbH
material can be provided for each Gasanstaltstraße 2
Sunfire product.
01237 Dresden
Germany
W: www.sunfire.deYou can also read
