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Article history:
Received 8 November 2011
Received in revised form
18 January 2012
The solar thermochemical production of fuels such as
driven looping processes use water and CO2 as the sole feed-
stocks and concentrated solar radiation as the sole energy
source. Looping processes using natural gas [4e7] or coal-
production. This study uses iron/iron oxide redox pairs as the
iron oxides during the first reaction step. Coal-derived Syngas
is then passed through the oxides, reducing them back to iron
during the second reaction step. Since the gaseous products of
* Corresponding author. University of Florida, Department of Mechanical and Aerospace Engineering, 330 MAE-B, Gainesville, FL 32611,USA. Tel.: 1 352 392 9129.
Available online at www.sciencedirect.com
w.
i n t e rn a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 7 ( 2 0 1 2 ) 7 4 4 2e7 4 5 0E-mail address: [email protected] (J. Petrasch).hydrogen or Syngas using metal/metal oxide looping
processes [1e3] is considered an interesting route to carbon-
neutral fuels. The concept shows promise in helping to
satisfy a growing global energy demand, reducing oil price
volatility, and mitigating anthropogenic climate change. Solar
reactive material [10]. This process is capable of producing
significantly higher purity hydrogen than conventional coal
gasification and subsequent water gas shift [11,12]. Another
advantage is that the process avoids gas-phase separation.
Metallic iron is oxidized by steam, producing hydrogen and1. Introduction derived Syngas [8,9] as the reducing agent constitute animportant stepping-stone toward carbon-neutral hydrogenAccepted 19 January 2012
Available online 23 February 2012
Keywords:
Looping cycle
Hydrogen
Iron oxide
Thermochemical
Syngas
Coal0360-3199/$ e see front matter Copyright doi:10.1016/j.ijhydene.2012.01.074An incremental thermodynamic equilibrium model has been developed for the chemical
reactions driving a clean, hydrogen producing iron/iron oxide looping cycle. The model
approximates a well-mixed reactor with continuous reactant gas flow through a stationary
solid matrix, where the gas residence time is long compared to time constants associated
with chemical kinetics and species transport. The model, which computes the theoretical
limit for steam-to-hydrogen conversion, has been experimentally validated for the
oxidation reaction using an externally heated, 21 mm inner diameter, tubular fluidized bed
reactor. Experiments were carried out at 660 and 960 C with steam flow rates ranging from
0.9 to 3.5 g/min. For small flow rates, i.e., for long residence times, the experimentally
observed cumulative steam-to-hydrogen conversion approaches the theoretically pre-
dicted conversion. At a 960 C operating temperature, the measured hydrogen yield
approaches the theoretical limit (experimental yields are always within 50% of the theo-
retical limit), and the yield is insensitive to variations in the steam flow rate. In contrast,
the measured hydrogen yield deviates significantly from the theoretical limit at a 660 C
operating temperature, and strong variations in hydrogen yield are observed with varia-
tions in steam flow rate. This observation suggests that the reaction kinetics are signifi-
cantly slower at lower temperature, and the model assumption is not satisfied.
Copyright 2012, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rightsreserved.a r t i c l e i n f o a b s t r a c tDepartment of Mechanical and Aerospace Engineering, University of Florida, Gainesville, FL 32611, USAProduction of hydrogen via anThermodynamic modeling and
A. Singh, F. Al-Raqom, J. Klausner, J. Petras
journal homepage: ww2012, Hydrogen Energy Pron/Iron oxide looping cycle:experimental validation
*
elsevier .com/locate/heublications, LLC. Published by Elsevier Ltd. All rights reserved.
step [2]:
Fe 4=3 H2O/1=3Fe3O4 4=3H2;
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 7 ( 2 0 1 2 ) 7 4 4 2e7 4 5 0 7443the oxidation reaction consist of hydrogen and steam only,
the process can generate highly pure hydrogen through steam
condensation. Furthermore the reduction step yields highly
concentrated CO2 suitable for sequestration.
The suggested two-step process uses the same reactor for
both the reduction and the oxidation reaction. The solid
reactants remain in the reactor and streams of steam and
Syngas are alternatingly fed to the reactors [9]. In contrast, the
three-step steam-iron process [6,11e20] employs two separate
reactors for hydrogen production and iron oxide reduction
[21], hence necessitating the transport of hot solids between
reactors.
To evaluate the theoretical potential of the suggested two-
step process, an open system incremental thermodynamic
equilibrium model is developed for both the hydrogen
production (oxidation) step and the regeneration (reduction)
step. The hydrogen production step is also carried out exper-
imentally to study the validity of the thermodynamic model
and to determine the conditions for its applicability. Roeb
et al. [22] conducted a thermodynamic analysis for two-step
water splitting with mixed iron oxides including nickel-iron-
oxide and zinc-iron-oxide to evaluate the maximum
hydrogen production potential of coating materials using
FactSage software [23]. Their analysis showed that maximum
hydrogen yield is realized when (i) the reduction temperature
is raised to 1300 C, (ii) the water splitting temperature islowered below 800 C, and (iii) the oxygen partial pressureduring reduction is minimized. This is consistent with similar
findings by Singh et al. [9]. Roeb et al. have also validated the
effect of reduction temperature and oxygen partial pressure in
Nomenclature
cp Specific heat capacity, kJ kmol1 K1
G Gibbs free energy, kJ
g0i Reference Gibbs function of species i evaluated,
kJ kmol1
h Enthalpy, kJ kmol1
_m Mass flow rate, kg s1
M Molar mass, kg kmol1
mFe Mass of iron, kg
P Total system pressure, N m2experimental studies. However, they could not experimen-
tally verify the increased hydrogen yield at lower water
splitting temperatures of approximately 800 C. Theyconcluded that kinetics play an important role in the oxida-
tion step. Svoboda et al., have carried out a thermodynamic
study of the potentials and limitations of iron based chemical
looping processes for the production of high purity hydrogen.
They studied the FeeFe3O4 system for cyclic hydrogen
production in the temperature range of 400e800 K [8]. In their
analysis, they have evaluated the hydrogen yield at equilib-
rium for the steam oxidation of pure iron tomagnetite (Fe3O4).
In accordance with Singh et al. and Roeb et al., [9,22] their
theoretical results showed that lower oxidation temperatures
are favorable for attaining higher hydrogen yields. They have
also indicated that at lower temperatures, the reaction is
limited by kinetics.Dh 31:75 kJ=mol at 960 C; (1)
followed by the reduction step:
1=3Fe3O4 2=3CO 2=3H2/Fe 2=3CO2 2=3H2O;Dh 1:25 kJ=mol at 960 C: (2)
High purity hydrogen and magnetite are produced during
the first step. During the second step, magnetite is reduced
back to iron using Syngas as the reducing agent. Coking and
iron carbide formation may occur during reduction. These
products may react with steam in the oxidation processIn the current study, an incremental thermodynamic
equilibrium model is employed to predict the maximum
attainable reaction yields. The model approximates a well-
mixed reactor with continuous reactant gas flow through
a stationary solid matrix where the gas residence time is long
compared to time constants associated with chemical
kinetics. The model is validated experimentally for the
oxidation case using an externally heated tubular fluidized
bed reactor. The current study is limited to the oxidation
reaction of the looping cycle.
2. Thermodynamic analysis
The ideal two-step iron based looping process for the
production of hydrogen consists of the hydrogen production
ni Number of moles for a species i, kmol
mFe,init Initial mass of iron, kg
Pref Reference pressure, N m2
PID Proportional-integral-derivative
R Universal gas constant, kJ kmol1 K1
sLPM Standard liters per minute
T Temperature, K
t time, s
yi,eq Mole fraction at equilibrium
yi Species i mole fractionproducing CO, CO2, and CH4 along with hydrogen. A detailed
analysis of the by-products of the reduction reaction has
been carried out in [9]. In the ideal process hydrogen is
completely consumed in the reduction reaction. However, in
real processes a large fraction of the hydrogen will not react.
The hydrogen and CO2 in the off-gases of the reduction step
may be separated via conventional techniques, such as
pressure swing absorption (PSA) [25] leading to lower purity
hydrogen.
An open system equilibrium model (Fig. 1) for a single
looping reactor is implemented. Small amounts of steam are
added to the system and the ensuing equilibrium reactant gas
mixture is removed from the system. Solid material remains
within the system. Assuming constant temperature and
pressure and ideal gas behavior, the species balance for
a gaseous component follows:
inside an aluminum chamber is used to generate vapor.
Stainless steel wool and a stainless steel screen are inserted in
the aluminum chamber to separate out water droplets and to
ensure dry steam discharges the steam generator. The steam
generator is thermally insulated with fiber glass insulation.
The rate of steam generation is controlled with a pulse-width
modulated signal (PMS) and solid-state relay at a frequency of
2 Hz. A 120 VAC power source provides power to the steam
generator. The steam is superheated to about 200 C bypassing it through an Omega Engineering, 1.37 cm outer
diameter (0.2500 NPT) 200 W in-line gas heater [30] that ismounted vertically and is capable of heating gas from an inlet
i n t e rn a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 7 ( 2 0 1 2 ) 7 4 4 2e7 4 5 07444dyi;gasdt
_nyi;gas;in yi;gas;eq
ngas;nsolid;T;P
yi;solid yi;solid;eqngas;nsolid;T;p
(3)
Species considered in the thermodynamic reactor models
are H2, H2O, CH4, C, CO, CO2, Fe, FeO, Fe3O4, Fe2O3, FeCO3, O2,
and Fe3C. Equilibrium compositions for the open system
oxidation/reduction process are calculated using Gibbs free
energy minimization,
yi;gas=solid;eqngas;nsolid;T;p
arg minngas ;nsolid
Gngas;nsolid;T;P
(4)
where
ngas n1;gas;n2;gas;.;nn;gas
nsolid n1;solid;n2;solid;.;nm;solid
yi;gas ni;gasPni1ni;gas
; yi;solid ni;solidPni1ni;solid
(5)
The Gibbs free energy is calculated assuming two separate
phases in close contact, namely a mixture of ideal gases, and
a perfectly mixed incompressible solid.
G Xn
i1Gi;gas Xm
i1Gi;solid (6)
Gi;gas nig0i niRT lnyiP=Pref
;Gi;solid nig0i niRT ln yi (7)
The number of moles of all species, ni,gas and ni,solid is con-
strained such that the elemental balance of the total system is
satisfied. Reference values for enthalpy, entropy, and the
temperature dependent specific heat, cp, have been obtained
from the HSC 7.0 database [24].
A steady state model, coded in Matlab [26], has been
developed for the conceptual looping plant layout shown in
Fig. 2; the model features open system chemical equilibrium
analysis, heat andmass balance on the reactors, and heat and
mass balance on the heat exchangers. The model is used to
predict reactor yields and identify the amount of reactant
gases necessary to achieve satisfactory conversion. Analyses
have been carried out for the temperature range between 27 Cand 960 C, at an operating pressure of 1 bar [9].
Fig. 1 e Equilibrium reactor diagram.2.1. Experimental facility
A bench scale experimental facility featuring a 21 mm inner
diameter tubular fluidized bed reactor for the iron/iron oxide
hydrogen production looping process has been fabricated. A
pictorial view of the hydrogen production experimental
facility is shown in Fig. 3 and a corresponding flow diagram is
shown in Fig. 4. The facility includes a 21 mm inner diameter,
0.6 m long fused quartz tube. Fused quartz is a non-crystalline
form of silica with a melting point of 1665 C [27]. To preventpowder carry-over, a 20 mm pore size stainless steel frit is
inserted at the top of the tube as depicted in reactor diagram
(Fig. 5). The powder is placed on a distributor made of
a Cotronics ceramic blanket thermal insulation material that
can withstand a temperature up to 1650 C [28]. The tube endsare sealed with stainless steel fittings using silicon O-rings
that canwithstand temperatures up to 300 C. The quartz tubereactor extends through an MTI electric furnace. The furnace
has a continuous operational range of 100e1000 C and canoperate at 1100 C for a short time span (less than 2 h). Thefurnace has a heating rate of 20 C /min. It is equipped witha PID controller and features 30 programmable segments (/1 C accuracy) [29]. The length of the furnace heating zone is300 mmwith a constant temperature zone length of 80 mm. A
K-type thermocouple is placed near the center of the furnace.
A steam generator consisting of four 200 W cartridge heaters
Fig. 2 e Conceptual looping plant layout.temperature of 121 C up to 540 C with a maximum gas
volumetric flow rate of 0.227 m3/min (8 CFM). Two water
cooled condensers are used. One condenser is used to deter-
mine the steam mass flow rate based on the volume of
condensate collected in a separate steady state measurement
prior to the experiment. The other condenser is used to
remove excess water from the hydrogen/steam mixture flow
discharging the reactor. The condensed water is accumulated
in a water trap and the weight of the water accumulated is
used to determine the amount of unreacted steam. The
volume of the produced hydrogen is determined by visual
Fig. 3 e Pictorial view of hydrogen production experimental facility.
Fig. 4 e Flow diagram of hydrogen production experimental facility.
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 7 ( 2 0 1 2 ) 7 4 4 2e7 4 5 0 7445
powder are used. The powder is mixed with 99.5% pure silica
in a 2:1 silica to iron volume ratio to retard sintering. The silica
Table 1 eWD experiment operating conditions.
Experiment # Steam mass flowrate (g/min)
Bed Ta (C)
1 3.5 0.2 956 72 1.9 0.1 962 73 0.9 0.1 950 74 3.5 0.2 641 55 0.9 0.1 681 56 1.9 0.1 693 5
a The temperature error for k-type thermocouples is estimated to
be 0.75% of the measured temperature [34].
i n t e rn a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 7 ( 2 0 1 2 ) 7 4 4 2e7 4 5 07446inspection of water displacement in an inverted graduated
cylinder at normal conditions (NTP, 20 C and 101 kPa). Theinverted graduated glass cylinders with 2000 ml capacity are
immersed in a water bath. Stainless steel sheathed E-type and
J-type thermocouples are used to monitor and record the gas
temperatures entering and exiting the tube reactor as well as
the temperatures of the fittings. A K-type thermocouple is
used to monitor the bed temperature. A National Instruments
data acquisition board, NI USAB-6225 [31], is used to collect
the thermocouple and flow meter voltage signals. A Labview
virtual instrument is used to observe, control and collect the
experimental data.
2.2. Description of experiments
Experiments are carried out to evaluate the water dissociation
(WD) step in the Iron/Iron oxide looping cycle. Reactor bed
temperatures of 660 and 960 C and steam mass flow rates of0.9, 1.9, and 3.5 g/min are considered. Table 1 lists the oper-
ating conditions for the six WD experiments. The total dura-
tion of the WD experiments ranges between 35 and 50 min.
High purity Ancor MH-100 porous iron powder with 99.56%
purity manufactured by Hoeganaes Corporation is used [32].
The iron is a porous powder with an average apparent density
of 2.5 g/cm3, a material density of 7.87 g/cm3 and a melting
point of 1536 C. Results of the iron powder sieve analysis areshown in Fig. 6. In each experiment approximately 25 g of iron
Fig. 5 e Schematic depiction of electrical furnace and
tubular reactor.(SIL-CO-SIL 63, U.S. Silica) sieve analysis is also illustrated in
Fig. 6 [33]. The mixed iron/silica bed is placed on the distrib-
utor in the quartz tube, which is then sealed with stainless
steel fittings. The quartz tube extends outside the electrical
furnace. The bottom portion of the quartz tube is insulated
with a ceramic blanket that is held in placewith stainless steel
bands to prevent steam condensation. A nitrogen flow is
passed through the reactor with a volumetric flow rate of 2
sLPM to heat the system to at least 150 C and to purge the airin the system, thus preventing oxidation of the iron powder.
In industrial practice, no nitrogen will be used, discharge gas
will be recirculates through the reactors. Using a three-way
valve, the steam is either directed to a condenser, which
empties into a graduated cylinder, or the steam is directed to
the reaction chamber. The mass flow rate of steam is
controlled via the heat input to the boiler. The exact steam
mass flow rate is determined by measuring the rate of
condensate when steam is directed to the condenser prior to
the actual experiment. The electrical furnace temperature is
set for the desired reaction temperature and held at the
temperature for the duration of the experiment. Once the
stainless steel fitting temperatures reach 150 C and the steamflow rate reaches steady state, the nitrogen is shut off, and the
steam is directed into the gas heater section, where it is
superheated and then directed to the reactor. Hydrogen and
excess steam leave the reactor and pass through a condenser
upon initiation of the oxidation reaction. The condensed
water is collected in a sealed cylinder (water trap). After theFig. 6 e Iron and silica powder size distributions by weight.
removal of all excess water, pure hydrogen is directed into an
inverted water-filled, graduated cylinder. The accumulated
amount of hydrogen is determined by visual observation of
the water displaced from the graduated cylinders.
2.3. Error analysis
An error analysis is used to assess the measurement uncer-
tainty. The steam mass flow rate is determined from the rate
ation for the steam mass flow rate error is listed in Table 2.
PH2 _mH2$t
43MH2MFe
mFe;initial
(9)
Table 2 e Uncertainty in steam mass flow ratemeasurements.
Steam mass flow rate (g/min) Uncertainty (g/min)
3.5 0.2
1.9 0.1
0.9 0.1
relative error.
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 7 ( 2 0 1 2 ) 7 4 4 2e7 4 5 0 7447T (C) _mH2O(kg/min)
t(min)
Uncertainty(ml)
H2volume(ml)
Relativeerror (%)
660 3.5 0e15 10 200 5.0
15etfinal 5 200 2.5The volumetric hydrogen yield is determined bymeasuring
the displaced water volume in an inverted graduated cylinder.
The uncertainty associated with the measurement involves
a visual inspection of the water meniscus. The water
meniscus reading is affected by the disruption of hydrogen
bubbles rising through the inverted cylinder. These disrup-
tions are more frequent at higher rates of reaction. The
measurement uncertainty and relative error (error in
meniscus reading) are estimated and listed in Table 3.
3. Results and discussion
The measured hydrogen yields using the fluidized bed of iron
particles at different steam flow rates are compared to the
Table 3 eHydrogen yieldmeasurement uncertainty andof the steam condensate accumulation. The measurements
are repeated, and the standard deviation (s) is used as
a statistical measure of the absolute error. The measurement
uncertainty is taken as s. For each operating condition, thesteam mass flow rate is measured twice. The standard devi-1.9 0e15 5 200 2.5
15etfinal 1 200 0.5
0.9 0e15 5 200 2.5
15etfinal 1 200 0.5
960 3.5 0e6 20 200 10.0
6e20 10 200 5.0
20etfinal 5 200 2.5
1.9 0e20 10 200 5.0
20etfinal 5 200 2.5
0.9 0e20 5 200 2.5
20etfinal 1 200 0.5theoretical open system incremental equilibrium yield at bed
temperatures of 660 and 960 C. Figs. 7 and 8 show thehydrogen yield as a function of the cumulative steam fed to
the reactor for the 660 and 960 C respective bed temperatures.The abscissa shows the ratio of the cumulative steam mass
flowing into the reactor to the stoichiometric steam mass
necessary for complete conversion of Fe to Fe3O4,
PH2O _mH2O$t
43MH2OMFe
mFe;initial
(8)
The ordinate shows the ratio of the cumulative hydrogen
mass discharging the reactor to the stoichiometric mass of
hydrogen that can be produced from complete conversion
from Fe to Fe3O4,
Fig. 7 e The Open system hydrogen production at 660 C
for flow rates of 0.9, 1.9, and 3.5 g/min.Fig. 8 e The Open system hydrogen production at 960 Cfor flow rates of 0.9, 1.9, and 3.5 g/min.
Fig. 9 e The open system solid molar composition for the
i n t e rn a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 7 ( 2 0 1 2 ) 7 4 4 2e7 4 5 07448Fig. 7 shows that hydrogen yield increases with decreasing
flow rate (increasing residence time) and moves toward the
thermodynamic limit with increasing cumulative mass of
steam entering the reactor. The influence of slow reaction
kinetics at lower temperatures is clearly discernible. In Fig. 8,
the hydrogen production rate is observed to be relatively
insensitive to the steam flow rate because reaction kinetics are
enhanced at higher temperatures. The thermodynamic limit is
approached,particularly athigh cumulative steamthroughput.
The cumulative steam throughput is quite important since
there is an energy cost for water to steam conversion.
The sharp bends in the theoretical yield curves are asso-
ciated with completion of the oxidation of metallic iron and
the completion of oxidation of FeO respectively (see also Figs.
9 and 10). Most of the theoretical steam-to-hydrogen conver-
sion occurs with small cumulative amounts of steam. This
allows for high theoretical energy efficiencies, since little
hydrogen production step at 660 C.excess steam needs to be produced. However, even at high
temperatures, experiments do not match the steep initial rise
Fig. 10 e The open system solid molar composition for the
hydrogen production step at 960 C.in cumulative H2 production. The experimental curves also do
not exhibit the two sharp bends. This is due to non uniform
mixing of the solid phase.
Figs. 9 and 10 show the variation of the theoretical solid
phase composition as a function of the cumulative amount of
steam employed for the 660 and 960 C respective bedtemperatures. At higher temperature (960 C) relatively moreFe3O4 and Fe2O3 are formed. A small amount of elemental Fe
persist at the 960 C bed temperature.Figs. 11 and 12 show the total solid phase mass normalized
by the initial ironmass as a function of the cumulativemass of
steam into the reactor for the 660 and 960 C respective bedtemperatures. Both the theoretical limit of solid phase mass
and that inferred from experimental hydrogen production
data via a gas-phase mass balance are shown. In both figures,
the large symbols at the end of the experimental curves denote
the final mass determined via weighing at the end of the
Fig. 11 e Predicted total mass of the solid phase for
hydrogen production step at 660 C.experiment. The discrepancy is attributed to the breakdown of
Fe-particles swept away during the experiment as well as
incomplete extraction of the solid phase after the experiment.
Fig. 12 e Predicted total mass of the solid phase for
hydrogen production step at 960 C.
the reactor increases, the experimentally observed cumula-
tive steam-to-hydrogen conversion approaches the theoreti-
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 7 ( 2 0 1 2 ) 7 4 4 2e7 4 5 0 7449cally predicted values. The steep initial rise of the theoretical
yield shows the potential for efficient conversion of steam-to-
hydrogen. However, particularly at low temperatures and
during the initial reaction phase, experimental yields remain
significantly below the theoretical limit. Increasing the resi-
dence time partially alleviates these issues. At higher
temperatures reduction of the flow rate (i.e., increasing the
residence time) has only a marginal effect on conversion,
indicating very slow effective kinetics beyond a certain
Hydrogen yield. This is consistent with ongoing kinetic
modeling in which two distinct kinetic regimes, (i) a shrinking
sphere regime, and (ii) a diffusion-limited regime, has been
identified. Based on this study it is concluded that the diffu-
sion-limited regime proves a severe obstacle to efficient
reactor operation and should be avoided. A combination of
measures is suggested to overcome these obstacles: (i) mini-
mize the particle size as far as possible without unacceptable
mass losses to maximize the surface to volume ratio, (ii)
increase the gas-phase residence time, e.g., via recirculation,
and (iii) only partially reduce and oxidize the iron based
reactants to avoid the diffusion-limited regime.
Acknowledgments
Financial support for this study by the United States Depart-
ment of Energy under Award No. DE-FE0001321 is gratefully
acknowledged.
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i n t e rn a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 7 ( 2 0 1 2 ) 7 4 4 2e7 4 5 07450
Production of hydrogen via an Iron/Iron oxide looping cycle: Thermodynamic modeling and experimental validation1. Introduction2. Thermodynamic analysis2.1. Experimental facility2.2. Description of experiments2.3. Error analysis
3. Results and discussion4. ConclusionsAcknowledgmentsReferences