Process heat

Last updated

Process heat refers to the application of heat during industrial processes. Some form of process heat is used during the manufacture of many common products, from concrete to glass to steel to paper. Where byproducts or wastes of the overall industrial process are available, those are often used to provide process heat. Examples include black liquor in papermaking or bagasse in sugarcane processing.

Contents

Requirements

The required temperature of the process varies widely, with about half the industrial process heat having operating temperatures above 400 °C (752 °F). These higher-temperature processes can generally only be supplied by dedicated supplies like natural gas or coal, although pre-heating from other sources is also common in order to reduce fuel use. Those processes operating below the median can draw on a much wider variety of sources, including waste heat from other processes in the same industrial process. Resistive heating would in theory be a possible source of process heat but even as it converts nearly 100% of the supplied electricity to heat, it is obviously less efficient to burn a fuel in a thermal power plant to produce electricity only to use that electricity for process heat than to use the fuel directly. Thus this source of heat is only used where electricity from non-thermal sources (such as hydropower) is cheap and plentiful. Heat pumps which are commonly employed for home heating, warm water and other heat applications below 100 °C (212 °F) have too low a Carnot efficiency at high temperature differences between "hot" and "cold" end to be worthwhile. Some processes such as molten salt electrolysis provide the required process heat by the same electricity that is also needed to keep the endothermic reaction going. Heat is usually described by "grade" with higher temperatures having a higher "grade". This is because heat naturally flows from hot to cold and it is thus always possible to use a high temperature source of heat for lower temperature applications but not vice versa. As higher grade heat is more cumbersome and expensive to produce and as materials have limited heat resistance, there are efforts to reduce working temperatures wherever possible through the use of catalysts and fluxes. In equilibrium reactions where temperature is one of the factors influencing the equilibrium, temperature requirements can be reduced by removing the desired products in a continuous process. For example, if an equilibrium reaction between AB and CD produces AC and BD and the equilibrium can be shifted rightward by increasing temperature, continuously removing AC or BD from the reaction can serve to reduce the temperature requirements (c.f. principle of Le Chatelier). However, there are limits to this as the speed of reaction is also temperature-dependent. Catalysts can serve to increase the speed of reaction at any given temperature but they, by definition, do not shift the equilibrium.

Decarbonization

Process heat accounts for approximately 30% of all the fuel use in the manufacturing sector, and is the target of significant efforts to introduce new forms of carbon neutral or at least lower carbon process heat supplies. Some wastes - including waste tires - are commonly used as replacement fuels or mixed into conventional fuel at appropriate ratios. [1] Biomass is already in widespread use in industry, while geothermal, concentrated solar power and nuclear power remain experimental and are not currently economically competitive. A problem with using nuclear power for process heat is that commonly used pressurized water reactors have an operating temperature well below 400°C [2] and boiling water reactors work at lower temperatures still (around 285 °C (545 °F)). [3] The Advanced Gas-cooled Reactor - whose high coolant outlet temperature was an explicit design goal - has proven a technological dead end and no other high temperature nuclear power plant has ever entered widespread commercial operation as of 2022. [4] Some Generation IV reactor proposals would change this, allowing higher grade heat to be produced. Likewise geothermal heat sources often have relatively low temperatures, sometimes even requiring binary cycles for electricity generation. [5] [6]

A stopgap solution for decarbonization at the price of increased costs (ignoring carbon pricing) and lower round trip efficiency is the replacement of currently used fossil fuels by Power to X derived fuels. While this approach has the advantage of being usable with existing technology with minimal or no modification, it is less efficient than even resistive heating as the chemical processes required to turn electric energy into artificial fuels are less efficient than resistive heating. In processes where the fuel provides both heat and a chemical function (e.g. coke as a reducing agent in steelmaking) a power-to-x fuel may however be the only feasible low carbon alternative for some time to come. Hydrogen derived via processes such as electrolysis of water is often proposed as an alternative to current sources of process heat. Hydrogen is already in widespread use in industry today but is mostly derived from fossil fuels via processes such as steam reforming as of 2022. As some proposed processes for hydrogen production like the sulfur-iodine cycle themselves require high temperatures, their feasibility for generating hydrogen as a fuel for process heat as opposed to the direct use of the heat needed for the process seems questionable.

Related Research Articles

<span class="mw-page-title-main">Haber process</span> Main process of ammonia production

The Haber process, also called the Haber–Bosch process, is the main industrial procedure for the production of ammonia. It is named after its inventors, the German chemists: Fritz Haber and Carl Bosch, who developed it in the first decade of the 20th century. The process converts atmospheric nitrogen (N2) to ammonia (NH3) by a reaction with hydrogen (H2) using a metal catalyst under high temperatures and pressures. This reaction is slightly exothermic (i.e. it releases energy), meaning that the reaction is favoured at lower temperatures and higher pressures. It decreases entropy, complicating the process. Hydrogen is produced via steam reforming, followed by an iterative closed cycle to react hydrogen with nitrogen to produce ammonia.

Syngas, or synthesis gas, is a mixture of hydrogen and carbon monoxide, in various ratios. The gas often contains some carbon dioxide and methane. It is principally used for producing ammonia or methanol. Syngas is combustible and can be used as a fuel. Historically, it has been used as a replacement for gasoline, when gasoline supply has been limited; for example, wood gas was used to power cars in Europe during WWII.

<span class="mw-page-title-main">Gasification</span> Form of energy conversion

Gasification is a process that converts biomass- or fossil fuel-based carbonaceous materials into gases, including as the largest fractions: nitrogen (N2), carbon monoxide (CO), hydrogen (H2), and carbon dioxide (CO2). This is achieved by reacting the feedstock material at high temperatures (typically >700 °C), without combustion, via controlling the amount of oxygen and/or steam present in the reaction. The resulting gas mixture is called syngas (from synthesis gas) or producer gas and is itself a fuel due to the flammability of the H2 and CO of which the gas is largely composed. Power can be derived from the subsequent combustion of the resultant gas, and is considered to be a source of renewable energy if the gasified compounds were obtained from biomass feedstock.

<span class="mw-page-title-main">Energy development</span> Methods bringing energy into production

Energy development is the field of activities focused on obtaining sources of energy from natural resources. These activities include the production of renewable, nuclear, and fossil fuel derived sources of energy, and for the recovery and reuse of energy that would otherwise be wasted. Energy conservation and efficiency measures reduce the demand for energy development, and can have benefits to society with improvements to environmental issues.

<span class="mw-page-title-main">Cogeneration</span> Simultaneous generation of electricity and useful heat

Cogeneration or combined heat and power (CHP) is the use of a heat engine or power station to generate electricity and useful heat at the same time.

The hydrogen economy uses hydrogen to decarbonize economic sectors which are hard to electrify, essentially, the "hard-to-abate" sectors such as cement, steel, long-haul transport, etc. In order to phase out fossil fuels and limit climate change, hydrogen can be created from water using renewable sources such as wind and solar, and its combustion only releases water vapor into the atmosphere.

Hydrogen fuel refers to hydrogen which is burned as fuel with oxygen. It can be a zero-carbon fuel, provided that it is created in a process that does not involve carbon. There are many types of hydrogen like white, green, blue, grey, black, or brown hydrogen owing to the various methods of processes by which they come. It can be used in fuel cells or internal combustion engines. Regarding hydrogen vehicles, hydrogen has begun to be used in commercial fuel cell vehicles such as passenger cars, and has been used in fuel cell buses for many years. It is also used as a fuel for spacecraft propulsion and is being proposed for hydrogen-powered aircraft. The fuel technology has seen awakened interest from automakers who claim it is comparatively cheap and safer to incorporate into the modern vehicle architecture over recent challenges faced by electric vehicle makers.

<span class="mw-page-title-main">High-temperature electrolysis</span> Technique for producing hydrogen from water

High-temperature electrolysis is a technology for producing hydrogen from water at high temperatures.

<span class="mw-page-title-main">Steam reforming</span> Method for producing hydrogen and carbon monoxide from hydrocarbon fuels

Steam reforming or steam methane reforming (SMR) is a method for producing syngas (hydrogen and carbon monoxide) by reaction of hydrocarbons with water. Commonly natural gas is the feedstock. The main purpose of this technology is hydrogen production. The reaction is represented by this equilibrium:

<span class="mw-page-title-main">Sabatier reaction</span> Methanation process of carbon dioxide with hydrogen

The Sabatier reaction or Sabatier process produces methane and water from a reaction of hydrogen with carbon dioxide at elevated temperatures and pressures in the presence of a nickel catalyst. It was discovered by the French chemists Paul Sabatier and Jean-Baptiste Senderens in 1897. Optionally, ruthenium on alumina makes a more efficient catalyst. It is described by the following exothermic reaction:

<span class="mw-page-title-main">Water splitting</span> Chemical reaction

Water splitting is the chemical reaction in which water is broken down into oxygen and hydrogen:

<span class="mw-page-title-main">Sulfur–iodine cycle</span> Thermochemical process

The sulfur–iodine cycle is a three-step thermochemical cycle used to produce hydrogen.

<span class="mw-page-title-main">Supercritical carbon dioxide</span> Carbon dioxide above its critical point

Supercritical carbon dioxide is a fluid state of carbon dioxide where it is held at or above its critical temperature and critical pressure.

<span class="mw-page-title-main">Electrolysis of water</span> Electricity-induced chemical reaction

Electrolysis of water is using electricity to split water into oxygen and hydrogen gas by electrolysis. Hydrogen gas released in this way can be used as hydrogen fuel, or remixed with the oxygen to create oxyhydrogen gas, for use in welding and other applications.

<span class="mw-page-title-main">Electric heating</span> Process in which electrical energy is converted to heat

Electric heating is a process in which electrical energy is converted directly to heat energy. Common applications include space heating, cooking, water heating and industrial processes. An electric heater is an electrical device that converts an electric current into heat. The heating element inside every electric heater is an electrical resistor, and works on the principle of Joule heating: an electric current passing through a resistor will convert that electrical energy into heat energy. Most modern electric heating devices use nichrome wire as the active element; the heating element, depicted on the right, uses nichrome wire supported by ceramic insulators.

<span class="mw-page-title-main">Steam-electric power station</span>

The steam-electric power station is a power station in which the electric generator is steam driven. Water is heated, turns into steam and spins a steam turbine which drives an electrical generator. After it passes through the turbine, the steam is condensed in a condenser. The greatest variation in the design of steam-electric power plants is due to the different fuel sources.

Hydrogen production is the family of industrial methods for generating hydrogen gas. As of 2020, the majority of hydrogen (~95%) is produced from fossil fuels by steam reforming of natural gas and other light hydrocarbons, partial oxidation of heavier hydrocarbons, and coal gasification. Other methods of hydrogen production include biomass gasification, methane pyrolysis, and electrolysis of water. Methane pyrolysis and water electrolysis can use any source of electricity including solar power.

The Glossary of fuel cell terms lists the definitions of many terms used within the fuel cell industry. The terms in this fuel cell glossary may be used by fuel cell industry associations, in education material and fuel cell codes and standards to name but a few.

<span class="mw-page-title-main">Proton exchange membrane electrolysis</span> Technology for splitting water molecules

Proton exchange membrane(PEM) electrolysis is the electrolysis of water in a cell equipped with a solid polymer electrolyte (SPE) that is responsible for the conduction of protons, separation of product gases, and electrical insulation of the electrodes. The PEM electrolyzer was introduced to overcome the issues of partial load, low current density, and low pressure operation currently plaguing the alkaline electrolyzer. It involves a proton-exchange membrane.

<span class="mw-page-title-main">Reversible solid oxide cell</span>

A reversible solid oxide cell (rSOC) is a solid-state electrochemical device that is operated alternatively as a solid oxide fuel cell (SOFC) and a solid oxide electrolysis cell (SOEC). Similarly to SOFCs, rSOCs are made of a dense electrolyte sandwiched between two porous electrodes. Their operating temperature ranges from 600°C to 900°C, hence they benefit from enhanced kinetics of the reactions and increased efficiency with respect to low-temperature electrochemical technologies.

References

  1. "Von Altreifen zum Ersatzbrennstoff". 2 June 2022.
  2. "Pressurized Water Reactor (PWR) Systems" (PDF), Reactor Concepts Manual, USNRC Technical Training Center, archived from the original (PDF) on 2022-08-12
  3. "Boiling water reactor - Energy Education".
  4. "Advanced Gas Reactor - an overview | ScienceDirect Topics".
  5. "Geothermal Source Temperature - an overview | ScienceDirect Topics".
  6. Finger, John; Blankenship, Doug (December 2010). Handbook of Best Practices for Geothermal Drilling (PDF) (Report). Sandia National Laboratories. Archived (PDF) from the original on 2022-04-18.

Further reading