SOW_Preconditioner Integration-V5.docx

Appendix “B” Argonne National Laboratory

STATEMENT OF WORK

AMMONIA PRECONDITIONER SYSTEM INTEGRATION

2025/08/06 (Version 5.0)

1.0 Background

To offset the low-flame speed of pure ammonia, partial dissociation of ammonia to H2 is required to ensure minimal designs changes to existing turbine hardware. A schematic diagram of the ammonia fuel preconditioner is shown in Figure 1. In it, a stream of gaseous ammonia is passed through the preconditioner wherein the exhaust heat is harnessed to catalytically crack the incoming ammonia stream. For every mole of ammonia 46 kJ of heat is required and two moles of products are formed. The rest of the ammonia is bypassed, vaporized, boosted and mixed with the dissociated gas stream.

Figure 1 ammonia preconditioner functional diagram.

A schematic rendition of the P&I Diagram of the preconditioner is shown in Figure 2. The turbine combustor fuel injection pressure is 15 bara in Phase-I and 80 bara in Phase-II. The ammonia vapor stream, i.e., stations 5, 6, 7 and 8, is passed through a recuperator (HX-2) and a catalytic heat exchanger (HX-1). Exhaust from the turbine is routed through the hot side of HX-1 to harness the exhaust heat and heat up the catalyst to temperatures above 450oC. The dissociated gas at station 8 is boosted up to the fuel injection pressure. The liquid ammonia stream is quickly boosted to the fuel injection pressure using pump P1. It is subsequently vaporized in HX-3 and mixed with the dissociated gas in a mixer. The resulting gas is a mixture of Hydrogen, Nitrogen and ammonia and will be referred to as HYAM gas. In this design, the hot sides of HX-1 and HX-3 are in series to maximize the benefit of using exhaust heat.

Figure 2 A 1-Dimensional schematic of the preconditioner One dimensional modeling was performed to obtain the temperature and pressure ranges at various stations of the preconditioner. The details of this modeling along with estimated sizes of the components are given in Section 10.

2.0 Scope

The vendor will integrate various Argonne supplied components along with some designed/specified by him to build an integrated ammonia preconditioner system. This preconditioner should be capable of harnessing waste heat from a gas turbine/combustor to partially crack incoming fuel to supply pressurized gases fuel, a mixture of ammonia, H2 and N2. The vendor will design, fabricate required components and finally integrate them to obtain the specified functionality. The final unit should be designed to facilitate utility connections and connecting to combustor exhaust. A human-machine-interface will have to be developed, preferably in LabView, to facilitate data acquisition and control by an operator situated in the control room.

3.0 Objectives

Figure 3 A 2-Dimensional rendering of the preconditioner system A rendering of the preconditioner with all of the connections is shown in Figure 3. Pressure Transducers (PTs) and Thermocouples (TCs) installed at various locations enable an operator to monitor the operation of the preconditioner. The electronic signals used for feedback control are shown with dashed lines. The aim is to have all these systems integrated into one or two trailers/ containers/ skid mounted systems to facilitate easy transport to the test site and subsequently connected easily with the test cell hardware (see Figure 4).

Figure 4 Utility and Interface connections for the preconditioner.

In summary, the specific objectives of this effort are to build an ammonia preconditioner using both Argonne supplied components, as well as vendor supplied components. The specific functional requirements of the preconditioner are listed below:

Range: 0.25 to 2.0 MW.

Ammonia flow rate range: 7.5 to 60 g/s.

Ammonia dissociated fraction, : should be user selectable between 0.4 and 0.55.

Turbine exhaust temperature: 520oC (typical), 600oC (Max).

Required Functionality of the Human-Machine-Interface (HMI) HMI should preferably be developed using LabVIEW. It should display values of various transducers and also allow turning on/off the valves, pumps, etc. individually. Also, the integrity of the catalyzed heat exchanger (HX-1) is ensured by

· Minimizing spatial and temporal temperature gradients

· Not exposing the catalyst to atmospheric oxygen.

To facilitate this along with ease of operation, the following automated control sequences are recommended.

Startup

· V1 Open & V2 closed

· Burner Exhaust/ hot air slowly introduced to ensure ramp rate < 10oC/minute and (TC11-TC9) < 100oC.

· After TC11>500oC, slowly introduce ammonia through HX-1

· Above 20% load slowly close V1 & open V2 Shutdown

· Slowly ramp down fuel flow

· shut down fuel flow when load < 50%

· Close V1 and V2 Emergency Shutdown

· shut down fuel flow

· Close V1 and V2 Long-term storage

· Make sure PT6 and PT7 > 1.5 psi

· Pressurized nitrogen purge may be used

4.0 Tasks & 5.0 Deliverables

PHASE-I

Task-1: Mechanical design: develop specifications for missing components – HX-2, MFC1 and MFC-2. Develop mechanical drawings and share with Argonne for review.

Deliverables-1: Detailed mechanical drawings, specifications of vendor supplied components.

Task-2: Electrical Design: develop specifications for all the electrical components. Develop electrical drawings and share with Argonne for review.

Deliverables-2: Detailed electrical drawings, specifications of vendor supplied components.

Task-3: Data acquisition and Control: Develop specifications for NI chassis, modules, and any other instrumentation. Share specifications with Argonne.

Deliverables-3: Specifications of vendor supplied components and associated electrical diagrams.

Acceptance Critera-1:

(a) Receipt of deliverables as stated under each task.

(b) All components are appropriately sized to achieve the target flow rates, temperatures and pressures (see Table 4 and Table 5).

(c) Electronic design capable of facilitating operator process monitoring & control via. a remote computer connected using an ethernet cable.

(d) Electronic design that enables load variation 0.25 MW to 2 MW.

(e) Electronic design that enables the dissociated fuel fraction, , from 0.4 to 0.55.

(f) System Startup: Capability to use either facility supplied hot air, or a propane/NG burner supplied hot exhaust to warm up the Catator HX-1, HX-3 and HX-4. The control system should ensure TC11 temperature ramp rate < 10°C/minute to avoid detrimental thermo-mechanical conditions. Moreover, the temperature difference between inlet and outlet should not exceed 100°C during start-up, i.e., (TC9-TC11) < 100oC. The HX-1 unit is designed for a maximum operation temperature of 600°C.

(g) Dissociated gas cooling: Based on the compressor P2 design, the dissociated gas between HX-2 and P2 might need additional cooling. Hardware and control elements need to be incorporated to achieve this additional water cooling.

PHASE-II (pricing to be included with any supporting solicitation, award action to be initiated after Argonne approves PHASE-I submittals)

1. Fabrication and System Integration: perform mechanical, electrical and electronic integration. All systems should fit in a trailer/ container/ mounted on skids for easy transportation to the test site in Purdue. Considering the 13 ft. wide road access to the test site, preferred system sizes are two pieces of 20 ft x 8 ft footprint (see Figure 5 and Figure 6). Packaging method must be weather-resistant and capable of protecting equipment for 6 months. Access to equipment must be possible by rigging/ crane services offered by the vendor .

2. Shake down test-1: Perform leak checks. Check control of MFC and exhaust valve V1. All instrumentation should read reasonably correct values.

Accuracy of all thermocouple readings = ±2oC or better;

Accuracy of all pressure readings = ±1.5% FS or better;

3. Training: Share any training documentation and/or train Argonne personnel in the use of the preconditioner.

Acceptance Critera-2:

(a) Receipt of integrated hardware in good condition.

(b) Reports of leak checks that were performed.

(c) Demonstrated capabilities of the operator process monitoring & control system via. a remote computer connected using an ethernet cable. Prefer a LabView program for easy integration.

(d) Demonstrated capability to vary the load between 0.25 MW to sub 2 MW.

(e) Demonstrated capability to vary dissociated fuel fraction, , from 0.4 to 0.55.

(f) Demonstrated system successful startup, i.e., HX-2 heat up rate < 10°C/minute and (TC9-TC11) < 100oC.

(g) Demonstrated dissociated gas cooling that meets compressor P2 requirements. These are typically to 60oC.

Other Acceptance Criteria:

1) All electrical components should be NRTL compliant (i.e., should have UL or similar listing). In case an NRTL component is not available, the specifications (or data sheets) of the component shall be shared with Argonne. Argonne may perform a DEEI inspection of the component prior to its installation.

2) An ammonia gas detector should be installed inside the container. Electronic signals from the detector should be made available for integration with test cell safety to initiate corrective action.

6.0 Government Owned Property

To facilitate system integration, in this section, specifications of each of the components are given in detail. Any missing details that are required for integration will be provided by ANL after the award of the contract.

Components supplied by Argonne: HX-1, (HX-3 & HX-4) combination, compressor P2, P-1, P-3.

Components to be supplied by vendor: HX-2, MFC-1, MFC-2, REG, Valve V-1, NI modules, thermocouples & pr. transducers and other required hardware. Cooling hardware and controls between HX-2 and P2 to meet compressor P2 requirements.

Specifications of the components are given below.

HX-1 (Catalyzed heat exchanger, a.k.a. CataRex) Argonne will purchase from another vendor and supply. It is designed to dissociate 60 g/s of ammonia. Dimensions are as shown below. A 2-D dimensional drawing is provided as a part of this SOW.

This catalytic heat exchanger will be enclosed in a minimum of 2 inch thick insulation so that the outside surface temperatures are below 50oC. Physical connections to the rest of the skid will be ANSI stainless-steel or alloy steel flanges.

HX-2 (recuperator): To be supplied by vendor Designed for 60 g/s of vaporized ammonia on the cold side. (0.25 nitrogen + 0.75 hydrogen) on the hot side. Operating pressure 1.1 bara. Temperatures (oC) for two extreme cases are given in Table 1 and Table 2.

HX-3 (High Pressure Vaporizer) & HX-4 (Low Pressure Vaporizer): Argonne will supply drawings provided as a part of this SOW.

Both the vaporizers are constructed into a single block. Exhaust in and out are 500 mm Dia. The block is encased in 2” thick insulation to prevent heat losses.

P-1 (liquid pump) : Argonne will supply D04XASJNNEMG Wanner Hydra-Cell Pump is outfitted with a motor and Invertek VFD.

P-2 (Compressor/ Gas booster):

In due course of design, the final fuel delivery pressure, P4, was reduced from 80 bara to 12 bara. So, the final fuel delivery pressure for the compressor is 12 bara at the minimum. While we are willing to consider any gas compressor that meets these specifications, listed below are a few candidates. Please note that Argonne will directly purchase the compressor once the vendor provides specifications and a quote.

· Bruckhard, 4HS-A. Approx. 70 kW of electricity at 460 VAC 3.

· BAUER screw compressor OP-2024-10631 REV - GRU28-150. Approx. 112 kW of electricity at 460 VAC 3.

P-3 (Liquid Pump): Argonne will supply M03XKSJSFEHA Wanner HydraCell Pump with motor and VFD.

7.0 Security

NA.

8.0 Place of Performance

Fabrication, Integration, leak checks, electronic trouble shooting, etc. – at vendor site.

Final demonstration of a working system – at Purdue Zucrow labs.

Operator training – at Purdue Zucrow labs.

9.0 Period of Performance

Typical values given below

10.0 Details of Final Delivery Site

Test Cell#2 of Purdue Zucrow labs will be used for performance evaluation of the integrated preconditioner. As shown in Figure 5 the destination is served by a narrow 13 ft wide road with two sharp bends.

Figure 5 Aerial view of the proposed testing site.

Figure 6 drone view of the test location.

11.0 Summary of One-Dimensional Modeling

One-dimensional modeling of the performance of the system was performed. Main findings of this modeling are summarized below.

Assumptions Turbine Exhaust temperature, T_ex = 520oC Overall equivalence ratio of turbine, EQR = 0.3 Fuel = anhydrous ammonia, NH3

Design Targets Combustor size = 2 MW Fraction of fuel dissociated, = 0.4 to 0.55 (user should be able to set the value) Useable range = 1 to 2 MW.

Fuel injection pressure = 80 bara.

** In due course of design, to keep the cost and size manageable, the final fuel delivery pressure was reduced from 80 bara to 12 bara. This change does not alter the specifications of the components except for that of the gas compressor, P2.

Two sets of calculations were performed while assigning reasonable values for several parameters. The P and T values at several locations for = 0.4 and = 0.55 are given in the tables below.

Table 1 Thermal conditions for = 0.4

Table 2 Thermal conditions for = 0.55

For each of the cases, the heat transfer occurring in each of the heat exchangers is given in the table shown below.

Table 3 Required Heat exchanger sizes

Table 4 Pressure Transducer Specifications

Max. Operational Temperature (oC)

Table 5 Thermocouple Specifications

oC

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