Work Package 2 „System Simulation“

Within this work package the existing 50 Nm3/h hydrogen generation system owned by HyGear is implemented into the simulation software Aspen Plus. An energetic evaluation based on the pinch-technology will be carried out to identify the achievable maximum system efficiency with thermal heat integration. Thereafter technical feasible options for heat integration will be evaluated in more detail. Constraints originating from the hydrogen generator setup and from results of the experimental investigations on component and material level will be considered. The energetic evaluation of the different heat integration options together with the experimental results of liquid desulphurisation and catalyst development will be the basis for the definition of the final system setup for the prototype unit. Additionally a set of simulations will be carried out by varying process parameters (T, p, S/C-ratio) in order to investigate their influence on system behaviour. Once the prototype is being built the Aspen Plus model will be adapted to the prototype setup and the simulation will be validated with experimental data of the prototype. Taking the technical feasibility into account the simulation results will be used to identify potential for optimization of the prototype in terms of heat management and H2-efficiency.

Description of work
The work in WP2 is broken down into 3 tasks:

2.1  Implementation of the existing 50 Nm3/h hydrogen generator into Aspen Plus  (DLR, m04 – m09)

  • Identification of the appropriate Aspen Plus property method
  • Implementation of sub-components according to system specifications defined in work task 1.1 (desulphurisation unit, reformer, water-gas-shift, pressure-swing-adsorption, burner, BoP components such as heat exchangers, pumps, tubing, etc.)
  • Implementation of liquid fuels as specified in work task 1.2
  • Assembling of components to overall process model
  • Variation of operating conditions such as temperature, pressure, and S/C-ratio
  • Variation of operating conditions of sub-components ( i.e. fuel-load and fuel-ratio (gaseous and liquid feed) for the dual-fuel burner) to investigate the influence on heat management and H2-efficiency of the overall system

2.2  Identification of suitable system setup with improved heat integration (DLR, HYG, JM, ABSR, APTL, IST, m10 – m18)

  • Energetic evaluation (DLR, HYG)
    • Thermal integration analysis of the process and realisation by internal heat exchange between sub-components and process streams. Special emphasis will be put on the fulfilment of the heat demand for the endothermic reforming reaction by burning PSA-offgas. (DLR)
    • Identification of external energy demand for heating/cooling (DLR)
    • Identification of process configuration with maximum theoretical system efficiency (energy efficiency and H2-efficiency) (DLR)
  • Consideration of technical feasibility (HYG, ALL)
  • Consideration of constraints on process level originating from experimental results (HYG, JM, ABSR, APTL, IST)

2.3  Validation of system simulation with test results (DLR, HYG, m22 – m36)

  • Adaption of existing Aspen Plus model to modified prototype set–up (DLR)
  • Identification of process parameters to be measured (DLR, HYG)
  • Validation of simulation with experimental data (DLR)

Identification of optimization potential in terms of heat management and H2-efficiency (DLR)