View
3
Download
0
Category
Preview:
Citation preview
1Ammonia Energy Association Conference 2021
100 kg/day Rapid Ramp NH3 System Development
Rachel Gregg M.S. , Ammonia Production EngineerAEA 2021
2Ammonia Energy Association Conference 2021
Starfire Energy is a clean energy company
● Research, development, deployment- Ammonia Synthesis and Cracking● Modular Ammonia Production following variable power
– Approach since 2016
– Ramp production based on power
– N2 and H2 used as they are made
NitrogenUnit
HydrogenUnit
Rapid RampNH3
AmmoniaStorage
Air
Water
CleanElectricity
H2
N2
NH3
Variable Renewable Power
3Ammonia Energy Association Conference 2021
Starfire Energy’s journey to 100 kg/day
● 100 kg/day system designed with modularization principals● Conex building block is first commercial NH3 synthesis product
– Each unit scaled to maximum capacity of standard shipping container– Faster, simpler, cheaper plant construction– Build any size plant from modules
ProofOf
Concept
LaboratoryScale
Reactor
10 kg/day Integrated
System
Scale Up & Modularization
EngineeringInvestigation
100 kg/day Modular System
2016-2017 2018 2019 2020 2021 2022
Conex Commercial
Design
4Ammonia Energy Association Conference 2021
Successful close of Series A investment in 2021
Funding transitioned from ARPA-E government funding to investment
5Ammonia Energy Association Conference 2021
The team and facility have expanded
Expansion of NH3 Synthesis team,
NH3 Cracking team, Fabrication
team, and Operations team
Facilities upgrade from4,000 to 23,000 ft2
2015 2016 2017 2018 2019 2020 20210
10
20
30
Starfire Energy Staffing
Year
# of
Em
ploy
ees
6Ammonia Energy Association Conference 2021
Process flow for NH3 synthesis
7Ammonia Energy Association Conference 2021
Next development step is the 100 kg/dayCirculation Pump
&Liquefaction
Reactor
Nitrogen Generation
Hydrogen Generation
Adsorption
Control and Power
8Ammonia Energy Association Conference 2021
100 kg/day system built in modules
● 6 main modules● Platforms
simulate 20 ft shipping containers
9Ammonia Energy Association Conference 2021
Nitrogen system fully installed and tested
Air Compressor
N2 Production System
Air DryerNitrogen
Generator
Nitrogen Booster
Air Storage● Several components
– Air compressor– Air dryer– Nitrogen generator– Boost compressor– Storage vessels
● 24 hour continuous test – 08:55 16-Aug to 08:55 17-Aug
10Ammonia Energy Association Conference 2021
N2 milestone complete in August 2021
Notes: 1. Step changes in N2 pressure are manual adjustments of pressure regulator.2. Spike in N2 flow rate resulted from rapid manual adjustment of regulator.
Not to exceed Milestone requirement
Actual System Performance
Actual System Performance
Must exceed Milestone requirement
Note 1
Note 2
Must exceed Milestone requirement
Actual System Performance
Test was successfulSKID achieved milestone requirements of pressure > 31 bar,
flow> 100 kg/day (4.17 kg/hr), and oxygen content < 10 ppm
11Ammonia Energy Association Conference 2021
Hydrogen system fully installed and tested
● 21 electrolysers, 5 dryers
● External water purification system
● Enapter supported commissioning
● 24+ hour continuous test – 07:00 24-Aug to 08:00 25-Aug
H2 Production System
Dryers(Top Unit on Each Rack)
Electrolyzers
12Ammonia Energy Association Conference 2021
H2 milestone complete in August 2021Test was successful
SKID achieved milestone requirements of pressure > 31 bar and flow> 20 kg/day (0.83 kg/hr)
Note 1. A power surge was experienced which shut down one electrolyser. Electrolyser was returned to operation after test completion.
Must exceed Milestone requirement
Must exceed Milestone requirement
Actual System Performance Actual System Performance
Note 1
13Ammonia Energy Association Conference 2021
Scaling the system resulted in design changes ● Reactor Vessel
– Was: 24” pipe 24” long– Now: 36” pipe 24” long
● Output increased by factor of 13.2
– Was:Thermal regeneration● Larger, Long Cycle Time
– Now: Novel regeneration technology
● Smaller Size = Faster regeneration, Lower cost
● More uniform flow
24” Reactor vessel 36” Reactor vessel
● Adsorber Vessel Regeneration
Previous adsorption bed
14Ammonia Energy Association Conference 2021
Experience curve drives cost reduction
● Ubiquitous in manufacturing● Break the normal cost reduction
approach to chemical synthesis– Traditionally reduce cost by increasing
unit size
● Mass produced modules reduces cost for both large and small plants
http://www.netmba.com/strategy/experience-curve/
Each doubling of cumulative production reduces cost 5 – 20%
15Ammonia Energy Association Conference 2021
Moving ahead
● Finish 100 kg design and fabrication
● Close Series B funding● Continue growing the team● Maximize capacity for conex
building block● Prepare for mass production
16Ammonia Energy Association Conference 2021
Questions?
Recommended