Use of Heat Pumps in the Hydrogen Production Cycle at Thermal Power Plants
Abstract
:1. Introduction
- Development and research of schemes for transferring real thermal power plants to a trigeneration cycle with the production of a new product—hydrogen—by the method of methane steam reforming;
- Increasing the efficiency of trigeneration plants by integrating a heat pump that uses waste heat from the power plant;
- Development of a methodology for determining the cost of fuel for the production of hydrogen in the trigeneration cycle of a thermal power plant.
- To develop a technological scheme for the production of hydrogen at TPPs;
- To propose a scheme for including HPUs in TPPs schemes to reduce the cost of hydrogen and reduce waste heat;
- To develop a methodology for determining fuel costs for hydrogen production in the cogeneration cycle of a thermal power plant.
2. Materials and Methods
2.1. Substantiation of the Choice of Hydrogen Generation Method
- -
- Use of industrial extraction steam with a flow rate of 30 t/h;
- -
- Use of industrial extraction steam with a flow rate of 90 t/h;
- -
- Use of steam from the live steam collector with a flow rate of 30 t/h;
- -
- Use of steam from the live steam collector with a flow rate of 90 t/h.
2.2. Schematic Solution for Integration of a Heat Pump
2.3. TPP Selection and Model Creation
- -
- CHPP has a live steam collector and production steam extraction;
- -
- The CHPP is located on the outskirts of Petrozavodsk, and, as a result, has the opportunity to expand the territory for new constructions;
- -
- The coefficient of utilization of installed capacity of the Petrozavodskaya CHPP in 2020 was 44.2%, in 2019—51.0%.
- Level of detailing for a heat-flow diagram of a simulated object is high;
- Models of equipment elements have been debugged and adjusted during many years of operation;
- Calculation accuracy of material and heat balance is high (10−6);
- There are several stages of testing at each step of model construction, calculation, and the analysis of calculation results;
- Graphical environment of the software is well developed; the results are visual.
- Creation of a mathematical model of an object, or design of a scheme;
- Parameterization of the mathematical model of the object, i.e., setting the parameters of the environment and the characteristics of the equipment for calculating the base case;
- Setting the operating mode of the object by entering the mode parameters.
2.4. Model Adequacy
2.5. Accounting for Hydrogen Production When Calculating Technical and Economic Indicators
3. Results and Discussions
4. Conclusions
- Using the example of a real thermal power plant, schemes have been developed and studied that allow switching cogeneration plants to a trigeneration mode with hydrogen production by integrating a methane steam reformer.
- To optimize the hydrogen production cycle, it is proposed to use heat pumps for preheating natural gas before the methane steam reformer.
- The use of a heat pump for the purpose of heating natural gas before MSRU does not have a significant impact on the operating modes of the combined heat and power plant due to its low power (1.47 MW). HPU efficiency indicator—the energy conversion factor—is low due to the large temperature difference between the LPHS (up to 27 °C) and the gas temperature at HPU outlet (95 °C). The use of a heat pump of a simple scheme for heating natural gas from a temperature of 15 °C to 95 °C saves only 0.16 thousand m3/h of natural gas. There is a need for additional research on the optimization of cycles and the consideration of other circuit solutions for heat pumps for joint operation with MSRU.
- A new methodology was developed for the distribution of fuel consumption in the production of a new product—hydrogen—at thermal power plants. This method can be adapted for use at various types of power plants.
- The minimum specific fuel consumption for hydrogen production—7.854 t ref.f./t H2—is achieved in the mode with steam extraction to MSRU from the turbine PT-60-130/13 (industrial extraction with a flow rate of 30 t/h). At this mode, the coefficient of fuel heat utilization is the highest among all modes with hydrogen production—66.18%, which is 2.3% lower than in the scheme without the use of MSRU. This is explained by the increase in the cost of electricity for own needs to ensure the operation of MSRU and HPU (7.39 MW).
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
Nomenclature
Abbreviations | |
APCS | automated process control system |
C | steam turbine condenser |
CCUS | carbon capture, utilization, and storage |
CFHU | coefficient of fuel heat utilization |
CHPP | combined heat and power plant |
Cm | HPU compressor |
CT | cooling tower of the circulating water supply system |
CWP | cooling water pump |
D | deaerator |
DRPS | desuperheating and pressure reducing system |
EG | electric generator |
Ev | evaporator |
HC | HPU condenser |
HPC | high-pressure turbine cylinder |
HPH | high-pressure heater |
HPU | heat pump unit |
LPC | low-pressure turbine cylinder |
LPH | low-pressure heater |
LPHS | low-potential heat source |
MB | main boiler |
MSR | methane steam reforming |
MSRU | methane steam reforming unit |
NG | natural gas |
NH | network heater |
PB | power boiler |
PCHPP | the Petrozavodskaya CHPP |
PWH | peaking water heater |
RNW | return network water |
ST | steam turbine |
ST1 | turbine unit PT-60-130/13 st. №1 |
TPP | thermal power plant |
UC | “United Cycle” |
VCHP | vapor compression heat pump |
Variables and Coefficients | |
Q0Σ | total heat output of steam boilers, MW |
QN | steam energy for electricity generation, MW |
Qind | steam energy for industrial steam extraction, MW |
Qh | steam energy for heat generation, MW |
BN | reference fuel consumption for electricity generation t ref.f./h |
Bref.f.Σ | reference fuel consumption at a CCHP, t ref.f./h |
Bind | reference fuel consumption for industrial steam generation t ref.f./h |
Bh | reference fuel consumption for heat generation t ref.f./h |
ΣN | power generation, MW |
ΣNON | electricity for own needs, MW |
QindON | industrial steam extraction for own needs, MW |
QhON | heat for own needs, MW |
bN | specific fuel consumption for electricity release, t ref.f./h |
bind | specific fuel consumption for industrial steam extraction release, t ref.f./h |
bh | specific fuel consumption for heat release, t ref.f./h |
BΣH2 | consumption of reference fuel for hydrogen production, t ref.f./h |
α | fraction of industrial steam extraction used for hydrogen production |
QindST1 | heat load of industrial steam extraction of ST1, MW |
Bref.f.ST1 | reference fuel consumption for industrial extraction, t ref.f./h |
QoST1 | thermal power of the ST1 turbine unit, MW |
Bref.f.MSRU | reference fuel consumption for the reaction implementation, t ref.f./h |
Bref.f.furn | reference fuel consumption for the MSRU furnace, t ref.f./h |
QH2 | thermal power of steam extracted for the MSRU needs, MW |
bH2 | specific reference fuel consumption for steam supply at MSRU, t ref.f./t |
GH2 | amount of produced hydrogen, t/h |
ΣQNH | thermal load of network heaters, MW |
ΣQBB | thermal load of built-in condenser bundle, MW |
Qcv.H2n = 33.8 Gcal/t | net calorific value of hydrogen |
1.163 | the coefficient for converting Gcal/h to MW: 1.163 MW = 1 Gcal/h |
Qcv.ref.f.n = 7 Gcal/t ref.f. | net calorific value of reference fuel |
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Parameter | APCS | UC | Note |
---|---|---|---|
Power, MW | 51.0 | 51.0 | Data are identical |
Live steam consumption, t/h | 264.0 | 255.9 | The difference is 3.0% |
Live steam temperature, °C | 544.0 | 545.9 | The difference is 0.3% |
Live steam pressure, kgf/cm2 | 122.0 | 122.0 | Data are identical |
Steam pressure in the industrial extraction chamber, kgf/cm2 | 12.6 | 12.6 | Data are identical |
Pressure in the condenser, kgf/cm2 | 0.103 | 0.103 | Data are identical |
Feed water temperature behind HPH-5, °C | 189.0 | 185.0 | The difference is 2.1% |
Feed water temperature behind HPH-6, °C | 215.0 | 210.7 | The difference is 2.0% |
Feed water temperature behind HPH-7, °C | 243.0 | 236.4 | The difference is 2.7% According to the documentation, the temperature of the feed water at the steam flow to the turbine is about 239 °C. Thus, the temperature at the outlet of the heaters of the HPH group is 2.3% higher than the calculated value. |
Feed water consumption, t/h | 260.0 | 260.0 | Data are identical |
Condensate temperature in the condenser, °C | 50.0 | 46.0 | The saturation temperature at the pressure in the condenser corresponds to a temperature of 46 °C. |
Condensate temperature behind LPH-4, °C | 117.0 | 117.0 | Data are identical |
Parameter | Value | |||
---|---|---|---|---|
Operating Mode | Industrial Steam Extraction | Steam Extraction from the Collector | ||
Steam extraction to MSRU, t/h | 30 | 90 | 30 | 90 |
Extracted steam temperature, °C | 285.6 | 275.6 | 494.3 | 494.2 |
Power underproduction factor, — | 0.61 | 0.58 | 1 | 1 |
Reduced fuel consumption due to higher temperature of extracted steam, thousand m3/h | 0.21 | 0.56 | 0.61 | 1.83 |
Temperature of LPHS before HPU, °C | 27.0 | 24.5 | 27.9 | 27.0 |
Temperature of LPHS after HPU, °C | 18.0 | |||
Methane consumption, t/h | 28.79 | |||
Temperature of methane before HPU, °C | 15 | |||
Temperature of methane after HPU, °C | 95 | |||
HPU power, MW | 1.47 | |||
Energy conversion factor of HPU, — | 1.53 | |||
HPU compressor power usage, MW | 1.32 | |||
LPHS consumption, t/h | 49.02 | 67.03 | 44.38 | 48.96 |
Reduced fuel consumption due to HPU, thousand m3/h | 0.16 |
Parameter | Value | ||||
---|---|---|---|---|---|
Operating Mode | Initial | Industrial Steam Extraction | Steam Extraction from the Collector | ||
Steam extraction to MSRU, t/h | - | 30 | 90 | 30 | 90 |
Electricity supply, MW | 231.84 | 224.45 | |||
Total fuel consumption, t ref.f. | 106.20 | 157.55 | 161.12 | 158.68 | 163.58 |
Change in total fuel consumption, % | - | 48.36 | 51.72 | 49.42 | 54.03 |
Fuel consumption for heat supply, t ref.f. | 46.94 | 46.97 | 47.03 | 47.01 | 47.03 |
Specific fuel consumption for heat supply, kg ref.f./MW | 130.61 | 130.70 | 130.86 | 130.80 | 130.86 |
Change in specific fuel consumption for heat supply, % | - | 0.07 | 0.19 | 0.14 | 0.19 |
Fuel consumption for electricity supply, t ref.f. | 59.26 | 57.62 | 55.04 | 58.68 | 57.40 |
Specific fuel consumption for electricity supply, g ref.f./(kW h) | 255.60 | 256.73 | 245.21 | 261.46 | 255.72 |
Change in specific fuel consumption for electricity supply, % | - | 0.44 | −4.06 | 2.29 | 0.05 |
Fuel consumption for hydrogen supply, t ref.f. | - | 52.95 | 59.06 | 52.99 | 59.15 |
Specific fuel consumption for hydrogen supply, t ref.f./t H2 | - | 7.854 | 8.759 | 7.858 | 8.773 |
CFHU, % | 68.39 | 66.18 | 64.72 | 65.71 | 63.75 |
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Kalmykov, K.; Anikina, I.; Kolbantseva, D.; Trescheva, M.; Treschev, D.; Kalyutik, A.; Aleshina, A.; Vladimirov, I. Use of Heat Pumps in the Hydrogen Production Cycle at Thermal Power Plants. Sustainability 2022, 14, 7710. https://doi.org/10.3390/su14137710
Kalmykov K, Anikina I, Kolbantseva D, Trescheva M, Treschev D, Kalyutik A, Aleshina A, Vladimirov I. Use of Heat Pumps in the Hydrogen Production Cycle at Thermal Power Plants. Sustainability. 2022; 14(13):7710. https://doi.org/10.3390/su14137710
Chicago/Turabian StyleKalmykov, Konstantin, Irina Anikina, Daria Kolbantseva, Milana Trescheva, Dmitriy Treschev, Aleksandr Kalyutik, Alena Aleshina, and Iaroslav Vladimirov. 2022. "Use of Heat Pumps in the Hydrogen Production Cycle at Thermal Power Plants" Sustainability 14, no. 13: 7710. https://doi.org/10.3390/su14137710
APA StyleKalmykov, K., Anikina, I., Kolbantseva, D., Trescheva, M., Treschev, D., Kalyutik, A., Aleshina, A., & Vladimirov, I. (2022). Use of Heat Pumps in the Hydrogen Production Cycle at Thermal Power Plants. Sustainability, 14(13), 7710. https://doi.org/10.3390/su14137710