Clariant supplying SNG catalyst for methanation unit in Audi’s new “Power-to-Gas” plant
21 October 2013
Clariant, a global provider of specialty chemicals, has supplied a proprietary CO2-SNG (synthetic natural gas) catalyst for the methanation unit of Audi’s new power-to-gas facility in Werlte, Germany. (Earlier post.)
The “e-gas plant” was started up in June this year and is part of Audi’s sustainability initiative. The plant, which can convert six megawatts of input power, will utilize renewable electricity for electrolysis, producing oxygen and hydrogen, the latter which could one day power fuel-cell vehicles. Because there is not yet a widespread hydrogen infrastructure, however, the hydrogen is reacted with CO2 in a methanation unit to generate renewable synthetic methane, or Audi e-gas.
The e-gas plant will produce an average of 1.4 million cubic meters of renewable synthetic methane per year, chemically binding some 2,800 metric tons of CO2 and equivalent to supply 1,500 new Audi A3 Sportback g-tron vehicles with an annual mileage of 15,000 CO2 neutral kilometers. (Earlier post.)
The plant was developed, constructed and built by Stuttgart-based plant manufacturer ETOGAS GmbH (formerly SolarFuel). The technology can be also used to store surplus energy in the gas pipeline system and to balance energy supply against demand.
Clariant is one of the leading global suppliers of catalysts used in synthesis gas processes. These processes include those for the production of ammonia, methanol and hydrogen. Additionally, the company develops and offers catalysts and adsorbents for CO2 conversion and SNG technologies.
Earlier this year, Clariant announced that it has signed a long-term cooperation agreement with Wison Engineering Ltd and a subsidiary of Foster Wheeler’s Global Engineering and Construction Group to equip coal-based methanation plants based on VESTA technology in China, the world’s largest SNG market, with catalysts of Clariant.
The power-to-gas methanation technology has been under development since 2009. The Center for Solar Energy and Hydrogen Research in Stuttgart, an R&D partner of ETOGAS and long-term cooperation partner of Clariant’s Business Unit Catalysts, initially developed the technology and successfully operated different CO2 methanation pilot plants with Clariant’s SNG catalyst.
Clariant is also part of iC4, a R&D cooperation of major participants from the chemical and energy sectors. The goal of this three-year R&D project is to develop new materials, catalysts and processes for Carbon Capture, CO2 Conversion to SNG and Carbon Cycling applications. The project is funded by the German Federal Ministry of Education.
We are proud to cooperate with AUDI/ETOGAS in this important flagship project. It is our strategic goal to increase business value through innovation and SNG is a clearly defined growth market for Clariant’s catalyst business. The new power-to-gas facility impressively demonstrates that SNG technology is an attractive solution for CO2 utilization, energy storage as well as future clean energy supply.
— Hariolf Kottmann, CEO of Clariant
many are interrested to buy these catalysts, e-gas, hydrogen, fuelcell cars, etc.
Posted by: Gorr | 21 October 2013 at 08:28 AM
6 MW (continuous) * 8760 hr/yr = 52600 MWh/hr
1500 vehicles * 15000 km/vehicle/yr = 22.5 million km/yr
Efficiency = 5.26e10 Wh/hr / 2.25e7 km/yr = 2300 Wh/mile.
A typical PHEV gets in the range of 200-300 Wh/mile. 2.3 kWh/mile is pathetic.
Posted by: Engineer-Poet | 21 October 2013 at 12:01 PM
Excuse me, that's 2.3 kWh/KILOMETER, pushing 4 kWh/mile. Even worse.
Posted by: Engineer-Poet | 21 October 2013 at 12:02 PM
To engineer-poet, this is efficient and this is not pathetic at all. You cannot plug a big windmill to the grid as impedance is not even but with this process you can harness efficiently wind power with his inconstant electric impedance as you can always match the output of the windmill and also store the fuel and fill up the car in 5 minutes. All in all a way better method then recharging electric-car with wind energy as you imply. Don"t just trow in stupid numbers, this is not the picture. Storing wind energy with variable impedance and matching this impedance with a car on the road that also use variable impedance have been the long time goal reached by these engineers, and they have nail down a good method for ice cars and future hydrogen fuelcell cars and trucks.
Posted by: Gorr | 21 October 2013 at 04:55 PM
“this is efficient and this is not pathetic at all.”
It is very inefficient and pathetic to the point of being a scam. When an automaker does a scam we accept it as marketing. E-P has correctly simplified the issue by looking at the amount of energy to do a certain amount of work.
Before doing a calculation, the problem must be defined. Generally speaking every time energy changes form, you lose efficiency. For example, I like to sail. Wind kinetic energy is converted to work when the boat moves through the water.
I could use a wind turbine to make electricity to turn a motor or charge batteries. The motor and batteries introduces efficiency loses. However, I really do not care about efficiency since wind is a renewable energy. Depending on the wind speed, I adjust the sail area to use the amount of wind I need.
The point here is to figure out the best way to use a resource. Converting wind kinetic energy to electricity to reduce fossil fuel use is simple and straight forward.
Here is where E-P is wrong. Charging PHEV increases the use fossil fuel. The assumption E-P is making that there is excess wind power is not valid, therefore he is wrong.
Converting electricity, no matter how it is made, to methane, storing the methane, then making electricity with methane is less efficient and therefore still wrong.
The common mistake nice folks make with renewable energy is think that the resource is unlimited without considering the equipment is limited. Clearly renewable energy can be used as a resource but it will never be in excess.
Posted by: Kit P | 22 October 2013 at 09:34 AM
E-P,
I looked at the previous article about this project, and looked at your comment about the amortized cost. I thinked the calculation slipped a decimal:
"•...produces an average 56 W(th) of methane.
•Multiplied by 8766 hr/yr this is a total of 49 kWh(th)/yr of methane."
Should be
"•...produces an average 56 W(th) of methane.
•Multiplied by 8766 hr/yr this is a total of 491 kWh(th)/yr of methane."
That makes the numbers look much better: about 6 cents per kWh before energy costs. Yes?
Posted by: Energyfaq.blogspot.com | 22 October 2013 at 12:30 PM
Energyfaq, you are correct. I did indeed slip a decimal. That would make the energy+amortization about 11¢/kWh for the methane, exclusive of the CO2 input.
Putting 1.3¢/kWh electricity in to get 11¢/kWh methane out is about the same ratio we're looking at here.
For a.b to presume to lecture anyone about impedance when it's obvious that he doesn't know what the word means (at least not so far as being able to solve an equation for it) is hilarious.
There's other hilarity here, but it's so obvious I don't need to spell it out. The cognoscienti are in on the joke.
Posted by: Engineer-Poet | 22 October 2013 at 06:31 PM
E-P,
How did you estimate $1,000 per kW?
Nick
Posted by: Energyfaq.blogspot.com | 24 October 2013 at 01:48 PM
The figure of €1000/kW(e) came from here, page 131. Current cost is much higher.
Posted by: Engineer-Poet | 26 October 2013 at 08:53 AM
E-P,
Thanks.
I wonder why the German approach is so focused on methanation? The simplest, cheapest approach (IMO) would be simple electrolysis to H2, with the H2 stored underground. Both electrolysis and underground storage are old and cheap, and you can generate power directly from H2 pretty much as easily and cheaply as from methane.
Methanation adds substantial costs and complexity, so I don't see it's appeal.
Nick
Posted by: Energyfaq.blogspot.com | 27 October 2013 at 02:10 PM
Methanation lets the gas be added to the existing NG distribution system, to give people the impression that it's doing some good. If they left it as hydrogen they'd have to work harder to make use of it, and it might become obvious just how little value is being produced for the money.
Posted by: Engineer-Poet | 28 October 2013 at 06:56 AM
There's no question that "power to gas" is inefficient, but if the input power is very cheap (less than 2 cents per kWh), and the total kWs relative small (5% or less of total annual kWhs), then that becomes less important.
Conventional storage, like pumped storage and chemical batteries, has very high capital costs for seasonal grid backup (which is only used a few times per year, so capex has to be amortized over very few cycles). P2G, on the other hand, can be very cheap per kW (heck, you can use very cheap ICE peak generators). So, P2G seems like a sensible answer for low volume but large peak power grid backup.
Does that make sense?
Nick
Posted by: Energyfaq.blogspot.com | 28 October 2013 at 09:31 AM
Isn't the feed-in tariff several times as high? Is wind etc. economic at 2¢/kWh? If not, who's going to pay the difference between the 2¢ which makes E-gas economic and the FIT price? What happens when the system runs out of Other People's Money?
All of this stuff has high capital costs; the Fraunhofer paper says around €2000/kW today and opines that it may get below €1000/kW sometime. You can figure what that comes to per average kW, based on the duty cycle for dispatchable loads (20% seems optimistic).
Resources aren't infinite. You can spend a lot of materials and labor building RE storage stuff, but that comes out of other consumption and exports. If these things can't pay for themselves quickly, you can run out of stuff to export to buy e.g. rare earths and even create hardship at home. The irony is that the RE-powered world has been the vision of the Limits to Growth camp, and they don't seem to realize that the same rules apply to them.
Posted by: Engineer-Poet | 28 October 2013 at 12:01 PM
Is wind etc. economic at 2¢/kWh?
No generator plant can pay the bills with 2¢/kWh, which is part of the reason that so many (including nuclear) are having so much trouble in many places right now.
But keep in mind, we're not talking about the majority of wind output: we're talking about off-hours: night time, and parts of the year when the output curve will rise above the production curve. At 25% efficiency, you only need overbuilding of 20% to get the 5% one needs for seasonal backup.
Also, at the moment power prices can go to zero, or even below. An energy sink like this would make both wind and nuclear much more economic.
All of this stuff has high capital costs
Not really. Remember, this is asymmetric: the equipment that captures surplus power can run 50% of the time, stockpiling output that will be used 5% of the time. The generation can be very cheap ICE. That means much less capital cost.
Which brings me back to H2 vs methane: electrolysis alone is much cheaper than methanation, so why go to methane?
Posted by: Energyfaq.blogspot.com | 28 October 2013 at 02:16 PM
the duty cycle for dispatchable loads (20% seems optimistic).
I take it you're referring to surplus power. Remember, this is a solution for seasonal variation, not diurnal variation. Diurnal variation is much cheaper to solve: pumped storage, DSM, V2G, chemical batteries will all work. That means a 50% utilization factor is realistic.
Posted by: Energyfaq.blogspot.com | 28 October 2013 at 03:29 PM
That's close to the O&M cost (including fuel) of the best-run nuclear plants, BTW.
When a very good wind site yields a capacity factor of 35%, I'm afraid that you ARE talking about the majority of output. There are loads which lend themselves to price arbitrage by time-shifting (particularly A/C, since ice is so cheap to make and store), but stashing electricity at 70% efficiency would require nameplate capacity roughly 4x the average load for that same 35% capacity factor. The price of the electricity that goes into the storage system is crucial, because that's going to be the bulk of sales.
This is only possible because of market-rigging by feed-in tariffs and per-unit tax credits. If not for that, RE generators would curtail their output to keep prices above zero.
The equipment that captures the power has to operate when there are surpluses to capture. If generators had a 90% or even 70% capacity factor, those surpluses would be relatively small and available much of the time... but they're not. A really good wind site may reach 35%, and PV is closer to 20%. While processes like methanation can go on around the clock, electrolysis has to be done when you have electricity. That sets the size and thus the capital expense of the major part of your chemical energy-storage system. The producers wouldn't get paid much; Fraunhofer writes this:
So it appears that the energy-storage wonks assume that the energy-generation wonks won't be making any money much of the time, or it'll come out of some third party's pocket as a feed-in tariff. This has "failure" written all over it.
Posted by: Engineer-Poet | 28 October 2013 at 04:16 PM
“No generator plant can pay the bills with 2¢/kWh, ”
Most large nukes and hydroelectric do just that.
“Also, at the moment power prices can go to zero, or even below. ”
Just how many hours a year do think this happens?
Posted by: Kit P | 28 October 2013 at 07:17 PM
E-P,
2¢/kWh...That's close to the O&M cost (including fuel) of the best-run nuclear plants
Yes, the last I looked the US O&M average was 1.9 cents. OTOH, that doesn't include capital investments, depreciation, major repairs, profit, etc. Nuclear (and coal) plants are now shutting down because they can't afford major repairs.
stashing electricity at 70% efficiency would require nameplate capacity roughly 4x the average load for that same 35% capacity factor.
Capacity factor is a bit misleading here. The thing that matters is average output. For instance, wind output would have to average about 220GW in the US to achieve 50% market share. If we were to overbuild wind to an average output of 275GW in order to reduce periods of low output in an optimal fashion (e.g., it might be cheaper than additional storage) then we would have an average surplus of 55GW.
The price of the electricity that goes into the storage system is crucial, because that's going to be the bulk of sales.
Ideally, most output would be used directly, thus eliminating conversion inefficiency. For instance, EV/PHEVs could automatically charge when prices were lowest (and nuclear/renewable output was highest relative to demand).
More importantly, P2G isn't a primary storage solution for daily time shifting. It's for that one week in January when there's no sun or wind. Realistically, it would be needed for only 5% of overall kWhs.
RE generators would curtail their output to keep prices above zero.
Sure - and that curtailed power is the "surplus" power we're talking about.
electrolysis has to be done when you have electricity.
Exactly. And, if you have an excess average output, that will be quite often. Remember, even with the skewed distribution of wind power over time, wind output is above average 45% of the time (half of all kids are below average!).
So, if we have sized the wind output at 20% over the average needed, then there will be surplus very roughly 75% of the time.
it appears that the energy-storage wonks assume that the energy-generation wonks won't be making any money much of the time
They assume that prices will be low much of the time, and proportionately higher at other times: this will incentivize market responses, including DSM, timeshifting, etc, etc, etc.
Kit,
power prices can go to zero, or even below....Just how many hours a year do think this happens?
Right now, not often. But, P2G is a long-term plan for a time when renewables have much higher market share - eventually, of course, fossil fuels will have zero.
Nick
Posted by: Energyfaq.blogspot.com | 30 October 2013 at 02:41 PM
No, capacity factor means a great deal. If you have 220 GW average at 55% capacity factor, your nameplate capacity (and potential peak generation) is 400 GW; if you have 27.5% capacity factor, you need 800 GW nameplate... which is roughly peak grid load, and far greater than the average. This has immense importance for the size and design of the storage systems RE requires to meet the goals set for it. The lower the capacity factor, the higher the peaks and the bigger (and more expensive) the storage system must be.
The beauty of nuclear power is that it can run at 100.0% capacity factor for a year at a time (though you could also load-follow if you needed to). Surpluses would not only be much smaller, but they'd be available on a very predictable basis. If you did use storage or dump loads, you'd get much more use out of them than with wind. This makes them economic at a much higher per-unit cost than with wind and solar.
If you have to overbuild to 800 GW to meet just half the demand on a grid with an average load of 450 GW, you are going to have many regular events where most of the output cannot be used directly.
The small batteries of PHEVs require them to charge almost every day (preferably, before every trip). If they don't charge many nights because the wind farms are becalmed, you lose a lot of the benefit of the PHEV (especially the carbon savings).
I don't see what else you're going to use. Once the PHEVs are charged (at half a Volt per capita and starting at 80% discharge, 1 kW/head of surplus would do that between 8 PM and midnight) you've got precious little else. You need to cycle something every few days in the all-RE scenario for the calm/cloudy periods.
In other words, there will be extensive periods when RE is essentially being given away and the generators are making no profit. This isn't compatible with a profit-driven growth scenario.
This is why I'm sure nuclear power is the key to unlock that door. Being able to run flat-out means that "surpluses" can be scaled to match expanded demand from DSM-capable loads. You don't have to worry about storage; your stockpile of stored energy isn't a chamber of compressed air or a pipeline full of gas, it's in tiny pellets of heavy metal which last literally for years.
Posted by: Engineer-Poet | 31 October 2013 at 03:12 AM
E-P,
I think we agree that: 1) either wind and nuclear would work alone, if absolutely necessary; 2 supply diversity is a good idea, and that a single source isn't likely to be anywhere close to optimal or lowest cost. Even without nuclear, you probably wouldn't want any single source to provide more than 50% of overall kWhs.
I agree that wind & sun have more variance than nuclear, and that that difference carries a cost, but I think you're overstimating how important that is. 1st, variance is smaller than that, and 2nd, there are a lot of relatively low cost solutions.
Okay, into details:
The lower the capacity factor, the higher the peaks and the bigger (and more expensive) the storage system must be.
A single turbine will often have zero or maximum output. A reasonably large windfarm will almost never have 100% output, and it will rarely go above 90%. Zero output will be rather less common. The Law of Large numbers tells us that every time we double the number of non-correlated wind farms, the ratio of variance to mean output will go down by very roughly 30%. US continental wind production would only rarely exceed 75% of the theoretical peak output. And, periods of very low output would be rare and not that long.
And, of course, in the real world we'd never rely on wind alone: we'd use sun, and geothermal, and wave, and biomass, etc. Many of those would be countercyclical, or consistent, or dispatchable.
overbuild to 800 GW to meet just half the demand on a grid with an average load of 450 GW, you are going to have many regular events where most of the output cannot be used directly.
It will certainly happen (maximum output during minimum demand), but the large majority of overall output will be used directly. See below re PHEVs.
The small batteries of PHEVs require them to charge almost every day (preferably, before every trip).
1st, The average mileage of 30 per day is an average. Many people will drive less than that. 2nd, even if charging every day is important, dynamic charging allows moving demand around by up to 8 hours - that helps a lot.
3rd, and most important, a world where wind & sun provided as much as 50% of the kWs would be a world in which almost all vehicles would be PHEvs or EVs, and the average battery would be much larger. 230M vehicles with 25kWh each gives 6 TWhrs of storage. That's enough to capture 250GW of excess production for up to 24 hours, and it would allow deferral of charging for a day or two for many drivers (incentivized by pricing, of course).
P2G isn't a primary storage solution for daily time shifting. - I don't see what else you're going to use.
There's quite a lot of demand that can be shifted around: industrial demand (steel smelting happens at night right now because of primitive DSM), I/C/residential HVAC, freezer and fridges, hot water heating, washing & drying all can be shifted to a greater or lesser degree. Heck, lighting could dim by 20% at periods of maximum stress without people noticing much.
And, of course, pumped storage, CAES, chemical batteries etc., all become feasible for daily load shifting.
Nick
Posted by: Energyfaq.blogspot.com | 06 November 2013 at 02:28 PM
I fear it's not so. All the high hopes for CAES in Iowa and the Ohio limestone mine have come to naught. There's ONE pumped storage site in my state, and no plans for more. Chemical batteries are just becoming competitive with petroleum, far too costly for mass storage of grid power (they're being used to keep power live during brief line outages in outlying areas, but that's not the same thing; V2G could add this with no incremental cost).
I once believed CAES would be a major player. I am now skeptical of this, because I don't see the progress that ought to have occurred by now. There are large opportunities for price arbitrage in electricity, if storage can just be made cheap enough. Turbomachinery is mature technology, so the problems have to be in the fundamentals. The nature of fundamentals is that they don't go away.
Posted by: Engineer-Poet | 08 November 2013 at 08:31 AM
Well, keep in mind the timeframes involved: major storage isn't needed yet, and won't be for a while. Also, there are a variety of solutions available, including DSM and V2G. Heck, major centralized utility storage may be viable as a solution, yet never become the lowest cost choice.
Things are unpredictable: who would have expected that day vs night arbitrage would become *less* important in some areas because of aboundant PV, and that pumped storage would start to be needed less than before??
Posted by: Energyfaq.blogspot.com | 08 November 2013 at 10:48 AM
Not yet? Try "some time ago". When unreliable power forced onto the grid under "must-take" laws and feed-in tariffs is forcing wholesale prices to zero and below, it's a sign that the system is broken. It either needs less unreliable power on the grid, or more places for it to go. Power-to-gas is a very broken attempt at the latter.
Both very limited, if the primary roles of the electric grid and vehicles aren't sacrificed to "renewability" (which the massive consumption of steel and concrete doesn't mock from the outset). P2G is an attempt to increase the amount of unreliable power connected to the grid, by acting as a dump load to soak up the peaks. The joke is that if you think power is expensive now, just wait until it all comes from "free fuel".
I recall that I did. It's pretty obvious.
It's hard to tell from the article, but it looks like the economics of pumped storage were hit by the anti-market cost structure imposed by law. The Energiewende calls for massive amounts of storage, but its own mandates are destroying even the bit that exists. This is the very essence of "broken". It cannot work, it's just a question of how much damage it will do before it is rescinded.
Posted by: Engineer-Poet | 09 November 2013 at 09:01 AM
When unreliable power forced onto the grid under "must-take" laws and feed-in tariffs is forcing wholesale prices to zero and below, it's a sign that the system is broken.
Low prices aren't really a problem. And, It's no different than we saw with nuclear, and we'd see much more if nuclear were to expand. Nuclear caused night time power to be very low, and they'd go much lower if nuclear expanded to 50% or more market share.
it looks like the economics of pumped storage were hit by the anti-market cost structure imposed by law.
They were hit by the expansion of solar, which reduced peak period prices. That's the same thing that would happen under a good stiff carbon tax. I'd prefer a free-market solution like a carbon tax (blocked by the fossil fuel industry), but the end result is pretty similar.
The fact is that we don't need much storage right now - the German grid is more reliable than ever. Plans for expanded storage are a matter of planning ahead in case of future need. And, of course, it may not be needed for quite a while - DSM, V2G, long distance transmission, supply diversity - all these are very powerful.
Posted by: Energyfaq.blogspot.com | 09 November 2013 at 12:45 PM
It is when the unreliable producers are not receiving those low prices, but fixed premium prices. People's money is being stolen through their utility bills to pay for things they can't use (otherwise demand would rise to meet supply), meanwhile raising the price of what they do need beyond some people's ability to pay for it.
If RE producers got paid wholesale rates like other generators, they would have to take measures to match up their supply with demand. This could be done by curtailing oversupplies, or arranging for schedulable demand. Of course, if RE producers got paid those rates there would be almost none of them on the grid in the first place. It's an industry created by government fiat.
It's very different. Nuclear is reliable; you can depend on the off-peak power being available every night and weekend. Dependability lets you make investments. You can't do much of that with supplies that are highly variable both hourly and seasonally with capacity factors as low as 11%.
That would be fine. Make it really cheap to charge EVs at night, heat water or charge "heat batteries", process garbage with plasma-arc gasifiers. Power you can rely on having every night lets you make such investments.
Posted by: Engineer-Poet | 10 November 2013 at 09:14 AM