Thermodynamic analysis of a high-temperature hydrogen...

Scientia Iranica B (2020) 27(4), 1962{1971

Sharif University of TechnologyScientia Iranica

Transactions B: Mechanical Engineeringhttp://scientiairanica.sharif.edu

Thermodynamic analysis of a high-temperaturehydrogen production system

Sh. Safary Sabeta,b, M. Mostafa Namara, M. Sheikholeslamia,b;�, and A. Shafeec,d

a. Department of Mechanical Engineering, Babol Noshirvani University of Technology, Babol, Iran.b. Renewable Energy Systems and Nano uid Applications in Heat Transfer Laboratory, Babol Noshirvani University of Technology,

Babol, Iran.c. FAST, University Tun Hussein Onn Malaysia, 86400, Parit Raja, Batu Pahat, Johor State, Malaysia.d. Department of Applied Science, College of Technological Studies, Public Authority of Applied Education & Training, Shuwaikh,

Kuwait.

Received 13 October 2018; received in revised form 25 December 2018; accepted 4 February 2019

KEYWORDSEnergy-exergyanalysis;HTSE;Renewable energy;Solar driven cycle;ORC.

Abstract. Using clean energy resources is considered as a major solution to globalwarming. Hydrogen is one of the most popular clean and renewable fuels, which haswidely been addressed by researchers in di�erent contexts from additive fuel of internalcombustion engines to pure feed of fuel cells. Hydrogen production is also one of the mostinteresting �elds of study and extensive e�ort has been devoted to �nding high-performance,fast, and economical approaches in this �eld. In this study, a novel high-temperature steamelectrolyser system with an integrated solar Brayton cycle core is proposed and numericallysimulated for hydrogen production. Energy and exergy analyses were carried out to gainbetter perception of the performance of the system and Rankine and Organic RankineCycle (ORC) were integrated with the main core to improve its e�ciency. The in uencesof di�erent parameters such as turbine inlet temperature, inlet heat ux from the sun,and compression ratio as well as the used organic uid were investigated based on the�rst and second laws. Results showed the high performance of the proposed system withmore than 98% energy e�ciency in hydrogen production besides its simplicity of use. Thehighest exergy destruction occurred when the power generation system absorbed sun heat ux (more than 54%) and the performance of the system could be enhanced by improvingthe heat absorbing technology.© 2020 Sharif University of Technology. All rights reserved.

1. Introduction

Dependence of the world on fossil fuels for transporta-tion, buildings, and electricity generation has sharplyincreased since the industrial revolution. Indeed,the life standards have increased as well. However,some concerns, e.g., regarding climate change, global

*. Corresponding author.E-mail address: [email protected] (M.Sheikholeslami)

doi: 10.24200/sci.2019.52022.2487

warming, acid rains, pollution, increase in sea levels,and ozone layer depletion, have also grown alongside[1]. Accordingly, the use of other sources of energy hasbecome more and more vital [2]. Researchers considerhydrogen as a renewable and clean alternative energyresource in di�erent areas from methanol production [3]to its use as a pure/additive fuel in internal combustionengines [4{7]. Although hydrogen abundantly exists onthe earth, it can only be found in the composition ofother materials. Consequently, hydrogen productionhas changed into one of the most interesting �elds ofstudy and extensive research has been carried out onimproving economic e�ciency of hydrogen production

Sh. Safary Sabet et al./Scientia Iranica, Transactions B: Mechanical Engineering 27 (2020) 1962{1971 1963

[8{10]. However, more studies are still needed toachieve higher exergy e�ciency and thermodynamicanalysis of di�erent systems is a proper domain of e�ortin this regard [11{13].

The use of renewable sources to produce hydrogencan be categorized into two main groups of low-and high-temperature electrolyzing. High-temperatureelectrolyzers are more e�cient than low-temperatureones because of good ion conduction at an elevatedtemperature [14,15]. However, they require moreinlet power and heat. The demanded heat andpower by these electrolyzers can be provided throughdi�erent thermodynamic cycles employing solar [16],wind turbine [17], nuclear [18], and geothermal [19]energy technologies. The solar based system proposedby Ozcan and Dincer [20] overall had 18.8% energyand 19.9% exergy e�ciency and they asserted that itcould be improved to 26.9% and 40.7%, respectively,employing the heat absorbed by the molten. Balta etal. [21] divided their solar based system into the powergeneration and hydrogen production sections. Theyreported that the energy and exergy performancesof the Power Generation System (PGS) were 24.79%and 22.36% and of the hydrogen production systemwere 87% and 88%, respectively. A conceptual designof photovoltaic solar energy conversion was presentedby Bhattacharyya et al. [22]. They estimated thee�ciency of their proposed thermodynamic and con-version module. Sayyaadi [23] utilized new a setup fordual hydrogen-power generation plant. The nuclear-based High-Temperature Steam Electrolysis (HTSE)proposed by Ozcan and Dincer [24] had 18.6% and31.35% energy and exergy e�ciency and the overall en-ergy and exergy e�ciency of the coal gasi�cation basedhydrogen production system proposed by Seyitoglu etal. [25] was 41% and 36.5% respectively. Moreover,exergy e�ciency of the biogas-based HTSE hydrogenproduction proposed by Abu�so�glu et al. [26] was25.83%.

In this paper, a high-temperature electrolyzer isemployed for hydrogen production. A Brayton cycleintegrated by solar energy is used to provide theelectrolyzer with the demanded heat and power. Inaddition, Rankine and Organic Rankine Cycle (ORC)are utilized to enhance e�ciency of the system. Inorder to compare two working uids of the ORC, theproposed system is analyzed under the �rst and secondlaws to �nd the best operating condition.

2. System de�nition

The proposed hydrogen production system has twomain parts, namely hydrogen production and powergeneration. The hydrogen production part is derivedfrom Ref. [27] in which hydrogen is produced via HTSEmethod. Through this method, the high-temperature

steam is divided into pure hydrogen and oxygen by thereceived electricity from PGS. The demanded heat isalso provided from the waste heat of the PGS. Twoheat exchangers are also utilized to use the heat ofthe separated hot hydrogen and oxygen, as shown inFigure 1. More details on HTSE and the employedheat exchangers are available in [27].

The power generation section consists of threecycles, namely, Brayton, Rankine, and ORC. Thedemanded power and heat by the electrolyzer areproduced through Brayton cycle. In this cycle, air iscompressed in a two-stage compressor via and inter-cooler, which cools it down to the ambient temperature.The feedwater to the electrolyzer is pre-heated by theabsorption of the inter-cooler waste heat. Then, thecompressed air is pre-heated in the solar receiver andmore heat is added to achieve the highest feasibletemperature due to the erosion of the turbine blades inthe combustion chamber. The energy of air is �rst con-verted to the power via the turbine and then, absorbedby the pre-heated feedwater to the electrolyzer. Then,the extra energy of air is employed to run Rankineand ORC boilers. Finally, a simple Rankine cycle andan ORC with regenerator are utilized to convert theextra energy of the air to the power. The generalcharacteristics of the integrated system are reportedin Table 1.

3. Model description

The equations for the �rst and second laws are em-ployed for each component to analyze the performanceof the integrated system. The required equations aregiven in this section and the following assumptions aremade to simplify modelling:

� All sections (PGS and the electrolyzer) are modeledby Steady-State Steady Flow (SSSF) process;

� The thermodynamic tables are used for the data onair, water, and CO2 properties;

� Pure methane is used as fuel for the combustionchamber;

� The out ows of the condensers of ORC and Rankinecycle are assumed saturated liquid;

� Air and combustion products are assumed as idealgases.

3.1. Energy analysisWith the above assumptions, mass conservation andenergy equation for each multi-input-multi-outputcomponent in the SSSF process [28] can be written as:X

_me =X

_mi; (1)

_Q� _W =X

_mehe�X _mihi: (2)

Here, _m and h are the mass ow rate and enthalpy and

1964 Sh. Safary Sabet et al./Scientia Iranica, Transactions B: Mechanical Engineering 27 (2020) 1962{1971

Figure 1. Schematics of the proposed system.

the subscripts i and e refer to inlet and exhaust ows,respectively. The correlations of ideal gas are employedfor the Brayton cycle [28]:

Pv = RuT; (3)

h = CpT; (4)

u = CvT: (5)

Here, the pressure, speci�c volume, temperature, andinternal energy of the working uid are shown byP , v, T , and u, respectively. Cp and Cv refer tothe special heat with constant pressure and volume,respectively, and Ru expresses the universal constant ofgases. Considering ideal gas as the working uid of theBrayton cycle, the outside temperatures of compressorsand turbine exhaust ows can be written as [28]:

TeTi

= 1� �tur

1��PePi

� k�1k!; (6)

TeTi

= 1� �comp

1��PePi

� k�1k!: (7)

In these equations, k is the ratio of special heatcoe�cients. Moreover, �tur and �comp refer to theisentropic e�ciency of the turbine and the compressor,respectively. In case of steam turbines and pumps,characteristics of the exhaust ows can be de�nedas [28]:

�tur =hi � hehi � hes ; (8)

�pump =hi � heshi � he : (9)

Here, the index es refers to the isentropic operation.All the processes of heat exchangers are assumed isobarand su�cient working pressure of the intercooler iscalculated as [28]:

Pintercooler =pP1P4: (10)

The sum of the generated/consumed power by turbines,compressors, and pumps is called net power and iscalculated for each cycle. In addition, the ration ofthe net power to inlet heat is called thermal e�ciency.As an example, for the proposed Brayton cycle, wehave [28]:


Table 1. General characteristics of the proposed system[21].

Solar towerReceiver height 65 mNumber of heliostats 69Total area of heliostat �eld 8349 m2

Brayton cycleWorking uid AirTurbine isentropic e�ciency 0.92Compressor isentropic e�ciency 0.88Compression ratio 11.2Turbine power capacity 5670 kWRankine cycleWorking uid WaterTurbine isentropic e�ciency 0.91Pump isentropic e�ciency 0.88Turbine inlet temperature 623.15 KTurbine inlet pressure 3000 kPaTurbine exit pressure 65 kPaTurbine power capacity 1020 kWORCWorking uid CO2

Turbine isentropic e�ciency 0.95Pump isentropic e�ciency 0.90Turbine inlet temperature 453.15 KTurbine inlet pressure 15000 kPaTurbine exit pressure 7000 kPaTurbine power capacity 445 kW

_Wnet = _WGT + _Wcomp1 + _Wcomp2; (11)

_Qnet = _Qreceiver + _QC:Ch; (12)

�I =_Wnet_Qnet

: (13)

The mass ow rates of inlet fuel, Rankine cycle, thefeedwater in the hydrogen production section andORC can be calculated considering the temperaturegradient of the hot side of heat exchangers by assumingadiabatic operations [28]:

_mmixCp;mix(T6 � T5) = _mfuel�combLHV; (14)

_mmixCp;mix(T8 � T7) = _mwater(h22 � h23); (15)

_mmixCp;mix(T9 � T8) = _mRankine(h12 � h13); (16)

_mmixCp;mix(T10 � T9) = _mORC(h17 � h18); (17)

where �comb and LHV refer to the combustion pro-cess e�ciency and Low Heating Value of the usedfuel, respectively, which are considered 0.98 and 47.13Mj/kg [29]. In addition, _mmix and Cp;mix are the mass ow rate and speci�c heat of the combustion products,respectively.

3.2. Exergy analysisSecond-law analysis, as another means of evaluatingthe performance of a device, can be carried out afterperforming the �rst-law analysis of each componentand de�ning thermodynamic properties of each steam.Thus, exergy balance equation is introduced as [28]:

_ExQ +X

_miexi = _ExW +X

_meexe + I; (18)

where _ExQ, _ExW , ex, and I are exergy transfers dueto heat transfer, exergy transfer from work, speci�c ex-ergy, and destructed exergy, respectively. Total exergyfor each steam is divided into thermo-mechanical andchemical exergy as [28]:

ex = extm + exch; (19)

extm = (h� h0)� T0(s� s0); (20)

exch =NXi=1

yiexich +RT0

NXi=1

yi ln(yi); (21)

where s and yi are entropy and the mole fraction of uidcompositions, respectively, and index 0 refers to thedead state, which is de�ned for working uid propertiesin ambient pressure and temperature. The exergy offuel is de�ned by a semi-empirical equation from [30]as:

" =exfuelLHV

; (22)

where " is considered close to unity. Exergy transferby the work and the passed heat from the systemboundaries [28] are:

_ExW = _W; (23)

_ExQ =�

1� T0

Ts

�_Q; (24)

where Ts refers to the temperature of heat source.Exergy e�ciency, as the more accurate criterion ofsystem operation, is introduced as the division of theachieved to the consumed exergy [28]:

=Exnet

Exi � Exe : (25)

For hydrogen production performance analysis, ther-mal e�ciency is de�ned as the ratio of the LHV of theseparated hydrogen from feedwater to the heat enteredto the system. For the second-law e�ciency, exergyof the separated hydrogen is compared with the inletexergy:


�I =_mH2;SepLHVH2

Qin; (26)

=ExH2;Sep

Exin: (27)

4. Results and discussion

Since the proposed system is based on a novel idea,experimental data are not available to validate theresults. Thus, each employed cycle is separatelyvalidated via given data from a previous study [21],which are shown in Table 2. As indicated, reliability ofthe generated results by the provided model is at a highlevel since the model has high accuracy in predictionof the system performance.

After de�ning the thermodynamic characteristicsof each steam, the home-made simulator model cancalculate the performance of the proposed system.The thermodynamic characteristics of each steam arereported in Table 3. The overall performance ofthe system was evaluated using the available databesides the de�ned equations in the section on modeldescription. The results are brie y given in Table 4.While 7532 kW of the total 8873 kW net power wasproduced by the Brayton cycle, almost 90% of the totalirreversibility was also from this cycle. The �rst lawe�ciency of PGS and hydrogen production was 50.7%and 98.3%, respectively.

The performance of the proposed system with thechange of Brayton turbine inlet temperature when theother inlet parameters are considered �xed are shownin Figures 2 and 3. The demanded fuel increasedby 36.8% to achieve 1600 K while the heat receivedfrom the sun had no change. The consumed fuelenhancement rate was greater than the turbine out-power rate. Therefore, the ratio of power to addedheat in combustion chamber slightly decreased. Fur-thermore, irreversibility of the general system increaseddue to higher heat transfer rate in heat exchangers

Figure 2. First-law analysis of the proposed system viaturbine inlet temperature.

Figure 3. Net power and irreversibility of PowerGeneration System (PGS) via turbine inlet temperature.

and hydrogen production e�ciency decreased by 6%due to the increase in fuel consumption by the rise inturbine inlet temperature. System response to inputheat ux from the sun is shown in Figure 4. With�xed turbine inlet temperature, less fuel was neededwhen the input heat ux increased. Consequently, the

Table 2. Comparison of reference and simulated data.

Cycle Energye�ciency

Exergye�ciency

Exergydestruction

[kW]

Powergeneration

[kW]

_mH2;produced_mH2;intered

(%)

Ref. [21] Sim.a Ref. [21] Sim. Ref. [21] Sim. Ref. [21] Sim. Ref. [21] Sim.

Brayton 38.7 38.79 47.71 50.7 206 2321 5670 5681 | |Rankine 24.21 24.22 40.19 63.72 1523 1137.2 1020 1015 | |

ORC 25.28 25.34 40.55 32.52 376 337 445 326.5 | |Simple PGS

(overal)24.79 24.79 22.36 27.15 17338 19030 7135 7022 | |

Simple HTSE(overal)

| 30.98 | 0.399 18130 20163 | | 66.62 65.43

aSim.: Simulation.


Table 3. Characteristics of each steam in the proposed system.

State no. Fluid T (K) P (kPa) _m (kg/s) h (kJ/kg) s (kJ/kgK) ex (kJ/kg)1 Air 298.2 101.3 14.24 298.6 5.696 0.02 Air 434.9 339 14.24 436.7 5.73 127.93 Air 298.2 339 14.24 298.6 5.349 103.34 Air 434.9 1135 14.24 436.7 5.383 231025 Air 903.6 1135 14.24 937.2 6.159 500.56 Air 1523 1135 14.24 1664 6.769 10457 Air 833.2 101.3 14.24 858.9 6.762 242.48 Air 759.4 101.3 14.24 777.8 6.66 191.79 Air 480.7 101.3 14.24 483.5 6.179 40.9610 Air 391.9 101.3 14.24 393.1 5.971 12.3811 H2O 361.1 65 1.582 368.5 1.169 24.5612 H2O 361.4 3000 1.582 371.9 1.169 28.0113 H2O 623.2 3000 1.582 3115 6.742 111014 H2O 361.1 65 1.582 2447 1.169 24.5615 CO2 301.8 7000 9.221 {213.9 {1.433 213.416 CO2 320.4 15000 9.221 {201.1 {1.433 226.317 CO2 367.1 15000 9.221 {58.1 {1.011 243.518 CO2 435.1 15000 9.221 81.55 {0.666 280.419 CO2 383.4 7000 9.221 33.3 {0.666 232.120 CO2 303.7 7000 9.221 {109.7 {1.088 214.821 H2O 298.2 101.1 0.85 104.8 0.3669 0.022 H2O 373.1 101.1 0.85 2418 1.306 17523 H2O 905.1 101.1 0.85 3776 9.172 104724 H2O 905.1 101.1 0.28 3776 9.172 104725 H2O 1185 101.1 0.28 4426 9.797 151126 H2O 905.1 101.1 0.57 3776 9.172 104727 H2O 1185 101.1 0.57 4426 9.797 151128 H2O 1185 101.1 0.85 4426 9.797 151129 H2 1233 10000 0.09 12881 60.77 1215130 O2 1233 10000 0.74 966.3 6.643 895.231 O2 907 7000 0.74 258.1 5.917 403.432 H2+H2 O 915 7000 0.09+0.02 3913 51.78 5865

Table 4. Performance of the proposed system.

Parameter ValueNet power 8873 kW

Net irreversibility 32.65 kWConsumed fuel 1.14 kg/sProduced H2 0.09 kg/s

�I;PGS 50.7%�I;H2 98.3%

ratios of produced power and hydrogen to consumedheat in the combustion chamber increased by 29% and13%, respectively.

Produced power and e�ciency of the Brayton cy-cle are a�ected by compression ratio and to investigateits impact on the system performance, it was changedbetween 8 and 16. In Figure 5, �rst- and second-law e�ciency, produced power, and irreversibility of

the Brayton cycle via compression ratio change areshown. All of them increased by rising compressionratio because of higher power generation rate of theturbine than power consumption rate of the compres-sor. Irreversibility also increased by 4.5 kW withincrease in the mean working pressure of the cycle.Considering Brayton cycle as the main power gener-ation core of PGS, total power increased with Braytoncycle. Indeed, higher temperature gradient of the inter-cooler due to isentropic temperature enhancement inthe compressor increased the total irreversibility by13.9%, as shown in Figure 6.

To investigate the role of working uid on ORCperformance, its energy and exergy parameters werecompared employing two di�erent working uids,namely carbon dioxide (R744) and ammonia (R717),as shown in Figures 7 and 8. In case of using carbondioxide as working uid, less net power was achieved


Figure 4. First-law analysis of the proposed system viasun heat ux.

Figure 5. First- and second-law analyses of Brayton cyclevia compression ratio.

and irreversibility decreased by 50% in ORC. Thesynergy of lower power and lower irreversibility ledto higher energy and exergy e�ciency when carbondioxide was employed as the working uid.

5. Conclusion

In this work, a high-temperature electrolzser integrated

Figure 6. Net power and irreversibility of PowerGeneration System (PGS) via compression ratio ofBrayton cycle.

Figure 7. Net power ORC and PGS via ORC working uid.

Figure 8. Irreversibility as well as energy and exergye�ciency of ORC via ORC working uid.

with a Power Generation System (PGS) was proposedand numerically simulated for hydrogen production.The system consisted in a solar-based Brayton cycledeveloped by Rankine and Organic Rankine Cycle


(ORC). Energy and exergy analyses were carried outand the following main results were obtained:

� The proposed system had more than 98% e�ciencyin hydrogen production;

� The power generation section had around 50% �rst-law e�ciency;

� The highest exergy destructor section was the solartower by losing more than 50% of the inlet sunirradiance;

� The proposed Brayton cycle could be more e�cientby focusing on reducing irreversibility in the solartower and combustion chamber;

� Increase in turbine inlet temperature decreased bothenergy and exergy e�ciency;

� ORC produced higher power with lower e�ciencyby employing ammonia as the working uid.

Acknowledgment

Authors acknowledge the funding support of BabolNoshirvani University of Technology through Grantprogram No. BNUT/390051/98.

Nomenclature

Abbreviations

HTSE High-Temperature Steam ElectrolysisPGS Power Generation SystemORC Organic Rankine CycleLHV Low Heating Value, kJ/kgUSUF Uniform-State Uniform-FlowSSSF Steady-State Steady Flow

English symbols

Cp Speci�c heat at constant pressure,kJ/kgK

Cv Speci�c heat at constant volume,kJ/kgK

Ex Exergy, kJex Speci�c exergy, kJ/kgh Speci�c enthalpy, kJ/kgI Irreversibility, kWk Heat transfer coe�cient ratiom Mass, kgP Pressure, kPaQ Heat transfer, kJR Gas universal constants Entropy, kJ/kg.K; Sun irradiance,

Wat/m2

T Temperature, Ku Speci�c internal energy, kJ/kg

v Speci�c volume, m3/kg

V Speed, m/s; volume, m3

W Work, kJ

Greek symbols

� First-law e�ciency� Density, kg/m3

Second-law e�ciency

Subscripts

0 Dead state1 Primary state2 Final statech Chemicalcomb Combustione Exhausti; in Inlets Sourcesep Separatedtm Thermomechanical

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Biographies

Shadi Safary Sabet is a BSc student in MechanicalEngineering at Babol Noshirvani University of Tech-nology. She has been working at the laboratory forrenewable energy systems and nano uid applicationsto heat transfer for a year and is now working on ther-modynamic simulation of power plants. Her researchinterests are green and renewable energy, power plantanalysis, and energy-exergy analysis of thermodynamiccycles.

Mohammad Mostafa Namar is a PhD candidateof Mechanical Engineering (Energy Conversion) witha broad and acute interest in the development of newinnovative thermodynamic cycles. He has been workingat the laboratory for renewable energy systems andnano uid applications to heat transfer since 2017 asa research assistant. His research interests are inter-nal combustion engine (SI, CI, LTC), thermodynamic

simulation of engine cycle, thermodynamics and heattransfer, and green and renewable energies.

Mohsen Sheikholeslami works in the Departmentof Mechanical Engineering at Babol Noshirvani Uni-versity of Technology, Iran. He is the Head of the Lab-oratory for Renewable Energy Systems and Nano uidApplications to Heat Transfer at the same university.His research interests are nano uid, CFD, simula-tion, mesoscopic modeling, nonlinear science, magne-tohydrodynamics, ferrohydrodynamics, electrohydro-dynamics, and heat exchangers. He has publishedseveral papers and books in various �elds of mechanicalengineering. He is the �rst scientist who developedthe Control Volume based Finite Element Method(CVFEM) in a reference book entitled Applicationof Control Volume Based Finite Element Method(CVFEM) for Nano uid Flow and Heat Transfer. He isalso the main contributor to the books Applications ofNano uid for Heat Transfer Enhancement, Applicationof Semi-Analytical Methods for Nano uid Flow andHeat Transfer, Hydrothermal Analysis in Engineer-ing Using Control Volume Finite Element Method,and External Magnetic Field E�ects on HydrothermalTreatment of Nano uid: Numerical and AnalyticalStudies, which have been published by ELSEVIER. Inthe reports of Thomson Reuters (Clarivate Analytics),he was a Web of Science Highly Cited Researcher (Top0.01%) in 2016, 2017, and 2018.

Ahmad Shafee works in Applied Science Departmentof the College of Technological Studies, the PublicAuthority for Applied Education and Training inKuwait. His research interests are ordinary di�erentialequations, special functions, nano uid, CFD, simula-tion, mesoscopic modeling, nonlinear science, magneto-hydrodynamics, ferrohydrodynamics, electrohydrody-namics, and heat exchangers. He has published severalpapers in di�erent journal.

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