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Article history:
Received 4 December 2014
Received in revised form 11 April 2015
Accepted 23 April 2015
Available online xxx
Keywords:
Energy conversion systems
Solid oxide fuel cells
Chemical looping combustion
Polygeneration
Oxyfuel combustion
Synthetic fuels
a b s t r a c t
In this perspective, an overview of the key challenges and opportunities in the design of new energy
systems is presented. Recent shifts in the prices of natural energy resources combined with growing
environmental concerns are creating a new set of challenges for process design engineers. Due to the
massive scale and impact of energy conversion processes, some of the best solutions to the energy crisis
lie in the design of new process systems which address these new problems. In particular, many of the
most promising solutions take a big-picture approach by integrating many different processes together
to take advantage of synergies between seemingly unrelated processes. This paper is an extended version
of a paper published as part of the proceedings of the 8th International Conference on the Foundations
of Computer-Aided Process Design (FOCAPD 2014) Adams (2014).
2015 Elsevier Ltd. All rights reserved.
1. Introduction
The current energy crisis is the result of the sum of human
activity, which essentially is to make and use energy. This crisis is
the result of several trends crashing together: the rise in population, the rise in global standards of living (measurable by energy
consumption), the depletion of nite energy and water resources,
the emission of greenhouse gases, and the sheer massive scale of
these activities. Complicating matters are geopolitics, the uneven
distribution of resources, social and political opinions, the complexity of global trade, and seven billion people making independent
decisions about their own best interests. It is a global problem with
no easy solution.
One good approach is the design of new energy conversion process systems. There is a signicant need to design new systems
which not only take into account recent advances in technology
and shifts in resource availability and demand, but also consider
sustainability as an integral part of the design methodology. This
means that any new candidate process system should not only be
environmentally sustainable, but also economically sustainable, as
well as politically or socially sustainable. A process which satises
all three categories meets what is called the triple bottom line of
sustainability (Elkington, 1997). In other words, the best processes
are those that are a good economic choice for a company to make
willingly without overly large government involvement; that have
a minimally negative (or even positive) environmental impact; and
that the general population is either supportive of or at least not
vocally opposed to the activity. Processes that satisfy the triple bottom line are the most likely candidates to help deal with issues
related to the energy crisis because they are the most likely to be
commercialized at meaningful scales, and they simultaneously are
better for the environment than the status quo. Because of the sheer
size of many energy conversion processes, even small improvements to efciency or emissions can have a massive effect when
applied to the global scale. This summarizes the grand challenge of
the process design engineer.
A convenient way of understanding the energy challenge is to
examine the energy return on energy invested (EROEI) for many
common energy conversion processes in use today and in the past,
as shown in Fig. 1. The EROEI is computed by taking the energetic
content of the product delivered divided by the energy required to
produce it. Ideally, the energy required for production includes the
cradle-to-gate energy expenditures along the entire supply chain
leading up to the production of that product over the entire life
time of that supply chain. This includes the direct energy consumed
during regular production of the product, but also the indirect
energy consumption associated with aspects further up the supply
chain (Poisson and Hall, 2013). This includes transportation fuels
required to transport intermediate products from place to place,
resource extraction, and the energy consumed during construction,
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Fig. 1. The energy return on energy invested for selected energy conversion processes. Data are approximate and can vary for each specic process and application.
All data from Murphy and Hall (2010), except Tar Sands (Poisson and Hall, 2013),
and Hydropower (Gagnon et al., 2002).
commissioning, and decommissioning of each stage (where signicant). The reader is referred to Murphy et al. (2011) for a full
description various EROEI methodologies.
For example, in the 1930s, the EROEI of oil production was about
100, meaning that about 100 barrels of oil could be produced by
consuming 1 barrel of oil (equivalent) to power the oil pumping and
related processes. In the 1970s, this dropped to 30 and is around 14
starting in the 2000s. Unconventional oil is worse, with tar sands
and shale oil at 45. Essentially, all of the low hanging fruit has
been plucked, not just for oil, but for all natural resources as reserves
deplete, forcing upstream recovery to move to deeper waters and
more extreme climates. This is also reected in renewable technologies, where we are currently developing (quite necessarily)
areas such as biofuels and solar thermal to prepare for an eventual low-resource future. Unfortunately, the processes seen as most
promising also have the most abysmal EROEIs at just above one
(anything below one is mathematically unsustainable for fuel production). We are gradually moving towards lower and lower EROEIs
for energy conversion in general, which is why quality process
design is such a critical component of the global solution.
In this perspective article, a brief overview of the state of natural
resources are presented, followed by a discussion of the new design
challenges and opportunities that result. Several energy conversion process opportunities are identied which have the potential
for signicant global impact, either through the design of new processes which take advantage of new or emerging unit operations,
or by the innovative integration of existing technologies into new
processes. The scope is restricted to thermochemical conversion of
non-renewable resources with a North American perspective.
2. What we have to work with
2.1. Non-renewable resources
It is helpful to examine the current state of our limited resources
in order to understand our options for future processes. Recently, a
signicant price disparity has arisen between oil and gas, as shown
in Fig. 2. Prior to the energy crisis of 2008, gas and oil had approximately the same price on an energy-content basis. However, in
2009, discoveries of shale gas reserves and advances in recovery
technologies sent a price shock from the sudden new supply of gas.
As a result, the oil price is currently 3.5 times the price of natural
gas on an energy-content basis (on February 1, 2015), even though
the price of crude has tumbled by almost $30 per barrel in the past
ve months. This price disparity is driving a rush of new interest
into using natural gas as a raw material to create energy products
traditionally produced by oil, which will be discussed in Section 4.
Based on the ratio of reserves to production, there is enough
supply of petroleum to meet current demand for 53 years. This
number should not be taken literally since it has actually been rising
as more oil becomes discovered or technically recoverable. In fact,
in 1984, the world oil supply was only at about 35 years (BP, 2014).
Nevertheless, as shown in the gradually diminishing EROEI in Fig. 1,
oil is becoming increasingly more difcult to obtain as recovery
shifts more towards tar sands, deep waters, and polar regions. The
quality of oil is also diminishing; the average API gravity rened in
the US has steadily declined by about 2 over the past thirty years
(Bacon and Tordo, 2005).
Conventional natural gas has a similar supply of about 55 years
with almost no change in this number from 1984 to 2014 (BP, 2014).
However, technically recoverable shale gas reserves are roughly
just as large (EIA, 2013b), bringing the total combined reserve to
around 109 years at present usage rates. Moreover, the future of
fossil methane will not likely end there, since there could be as
much as 10 1012 t of carbon (as CH4 ) locked into gas hydrates
located deep in rock beds offshore and in polar areas (Hester and
Brewer, 2009). Although it is not yet economical to unlock these
deposits, it makes sense to transition towards an increased use of
gas now, expecting to eventually replace the conventional and shale
gas sources with gas hydrates.
Coal is cheap and available, with a 113-year world supply (BP,
2014). For the range shown in Fig. 2, the cost of bituminous coal
has essentially always been cheaper than oil or gas on a per-energy
basis by a signicant margin, and enjoys a much reduced variability.
Despite the lower fuel prices, coal-based processes are generally
much more expensive in terms of capital due to the difculty of
solids handling, contaminants, and higher carbon content per Joule,
which results in generally more CO2 produced than gas in most
cases. Nevertheless, despite the dirtier nature of coal, several new
energy conversion processes have the potential to use coal wisely
such that all three aspects of the triple bottom line are satised.
Uranium, a non-fossil but non-renewable resource, is also
relatively abundant in economic quantities, with about an 80year world supply and rising (World Nuclear Association, 2012).
Although its primary (peaceful) use is for electricity production and
growth in this area is slowing, it is possible that new energy systems will be able to economically exploit its energy content for
other forms of energy production, which is discussed in Section
4.3. Similarly, thorium is about three times as abundant as uranium, and may be used as well, though this has not yet been widely
commercialized (World Nuclear Association, 2014).
2.2. Renewable resources
Theoretically, renewable solar resources (which include wind,
biomass, and hydroelectric) may be able to provide for all current
world energy needs of about 17 TW for all sectors including electricity, heat, industry, and transportation (de Castro et al., 2011).
Although estimates vary widely, wind energy could supply as much
as 38 TW (de Castro et al., 2011), hydroelectric up to 1.6 TW, and
direct solar (photovoltaic and concentrated solar thermal) as much
as 580 TW (Jacobson and Delucci, 2011). Although this means it is
still possible that humanity can exist at its present size and standard
of living using only renewables, this will not be possible for many
decades. For example, even though it is growing very quickly (about
25% annually), only about 0.05 TW of wind energy is in use today,
meaning that it will take 15 years to reach just 1 TW (de Castro et al.,
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Fig. 2. Approximate average US prices of oil (monthly, from EIA, 2014a), natural gas (monthly, from EIA, 2014b), and coal (from EIA, 2013a yearly prior to 2010, from
EIA, 2014c biweekly after 2010), on an energy basis, adjusted for ination to January 2014 US Dollars. Data were computed assuming 5.8 MMBtu/barrel of WTI crude and
adjusting for ination using the consumer price index (Bureau of Labor Statistics, 2014). Bituminous coal prices after 2010 use a weighted average of coal prices from the
Central Appalachian and Uinta basins to approximate the weighting used to compute prices prior to 2010.
2011). Direct solar sources have more potential but come with the
negative impact of blocking the light from whatever hopes to live
underneath. However, at present, the combined total production
by wind, solar, and hydroelectric makes up only about 3% of the
total world energy use.
Biomass will also play an important role, but with a signicant trade-off as growing biomass for energy purposes too often
competes directly with food and wildlife for land, with many resulting unintended consequences. Sustainable forestry and sustainable
agriculture techniques can be used to limit these effects, but such
development is ongoing and the trade-off can never be completely
prevented. However, using energy from biomass waste sources,
such as pulp and paper industry wastes, municipal solid wastes, or
discarded food products has the distinct advantage of very limited
competition with land and wildlife. For example, one can convert
waste cooking oil from deep fryers at restaurants into a useable fuel
(Zhang et al., 2003), and it makes little sense to grow potatoes just
to collect the waste oil from making fries. In fact, a secondary environmental benet may be realized from diverting waste biomass
away from landlls or treatment centres. Although helpful, the total
potential global energy production from waste bioenergy is estimated at about 0.5 TW, or only about 3% of current global energy
use (Gregg, 2010).
This illustrates the grand challenge for the energy conversion
systems community. We must develop new and better processes
which use our non-renewable resources in a more efcient and
environmentally friendly way so that we can safely and affordably
transition to a fully renewable world within the next century. We
can do this by developing new systems which incorporate existing
and/or research-level technologies which provide energy while satisfying the triple-bottom-line of sustainability, and by identifying
and developing new technologies or chemical unit operations (that
do not exist yet) which enable better systems. Some areas of opportunity for these are discussed in the rest of this article. Eventually,
we will have to gure out how to meet world energy needs perpetually on a xed upper bound renewably supply of about 620 TW.
Coal gasication can be used in the integrated gasication combined cycle (IGCC) power plant, shown in Fig. 3 (see Weil, 2010
and Sahraei et al., 2014 for detailed reviews of IGCC). The general
strategy is to gasify coal into syngas (a mixture of CO, H2 , H2 O, and
CO2 ), convert it to a mixture of H2 and CO2 using the water gas shift
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Fig. 3. (Left) Brief overview of the IGCC process. (Right) Temperature prole of the process gas. See Field and Brasington (2011) and NETL (2007) for process examples and
stream data.
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Fig. 4. Simplied sketches of (a) CLC for natural gas or syngas and (b) the coal oxyfuel process.
Fig. 5. An example SOFC power generation system with 100% CO2 capture. Heat recovered in the HRSG can be used for the generation of process steam, steam for turbines,
or municipal hot water or heating as desired. SOFC and fuel pressures can theoretically operate up to 20 bar (pressure drops not shown for brevity).
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collection and transport of the gas spread out over a vast area can be
quite expensive, especially where infrastructure is scarce. Developing nations are particularly susceptible to this problem. As a result
it is quite difcult to make a business case for converting the collected gases into a saleable product (Johnson and Coderre, 2012).
For example, if one were to invest in a gas-to-liquids plant (see
Section 4.1), it would be signicantly less risky and probably more
protable to make such a plant using conventional pipeline natural
gas instead of are gas. Therefore, there is a signicant opportunity for process engineers to come up with better systems that can
exploit this waste resource in a more cost effective way. A large
part of the problem is at the systems level, where the best solutions
are likely to involve changes along the entire supply chain of the
are gas, and will likely also require synergies with the associated
petroleum and gas recovery supply chains as well.
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Fig. 6. An example simplied process using SOFCs to co-produce power and fuels with zero direct CO2 emissions, using both coal and natural gas. Based on Adams et al.
(2013).
safety, training, and regulatory issues that might result. Furthermore, it can be difcult for a company who may want to co-produce
something that requires them to sell it to markets in which they
have no brand presence, experience, or relationships. And nally,
community opposition to any major novel chemical process may
present its own challenges, as is the case with the FutureGen
2.0 project in Illinois (Zeman, 2014; Talbot, 2014), Another challenge with polygeneration systems is that market conditions can
signicantly affect the business choices around which the best
processes can be made. Many studies have highlighted this for a
variety of applications, such as polygeneration systems which cogenerate FischerTropsch liquids and methanol products (Adams
and Barton, 2010; Khojestah Salkuyeh and Adams, 2013), i-butene
and ethanol (Martn and Grossmann, 2014), methanol and dimethyl
ether (Khojestah Salkuyeh and Adams, 2014), and olens and fuels
(Khojestah Salkuyeh and Adams, 2015b), each with electricity as an
additional major product. In each of these cases, the average lifetime market prices of the products strongly impacted the optimal
product portfolios, such that the optimal balance of co-products can
change signicantly. The impact of the oil price can have an equally
important effect. For example, high oil prices make the alternative strategies presented in this perspective look more attractive,
whereas low oil prices favour the status quo, and due to the strong
inuence of the oil price on world economies, it can be a very powerful inuence. Thus, there is a considerable risk associated with
the speculation of what future market prices will be over the long
term.
In order to help overcome these challenges, process system
engineers can demonstrate that the added value obtained by the
extra complexity is sufciently large enough to offset the costs
of overhead, bureaucracy, and uncertainty/risk associated with it.
In addition, by working closely with those involved in the nontechnical and business side of the process, engineers can attempt
to incorporate these issues during the synthesis phase of the
design.
6. Future challenges and opportunties for CAPE tools
Most of the computer-aided process engineering (CAPE) tools in
existence today are intended for use with specic areas of application. However, in order to achieve the grand challenge put forth in
this perspestivethat is, the design of more sustainable chemical
processes which help improve the triple bottom linethis requires
expertise across a wide range of disciplines and applications ranging from very big picture society-level impacts to very detailed
unit operation simulations. As a result, the process system engineers task is to conceive of a process, design it, simulate it, improve
it, optimize it, study it, evaluate its economics, determine the effects
of its uncertainty, understand its links to politics and society, and
assess its life cycle impacts on the environment. These steps are
often achieved in stages using different CAPE tools over a relatively
long period of time.
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affect the big picture economic view since rather rigorous capital and operating cost estimates can be determined in real time
and displayed right in the owsheet simulator. However, what
is needed is the ability to quickly and easily see how changes in
design parameters affect the big picture cradle-to-grave life cycle.
The integration of process simulation software with LCA software
should be substantially aided by the existence of open format standards for data exchange, in the form of CAPE-OPEN for process
simulation data and SPOLD for LCA data.
Although being able to see the impact immediately in external
software in some automated way is useful, having it available in the
same framework as the process simulator would allow the designer
to utilitze valuable tools already available in the simulation software like optimization, sensitivity analyses, and so on. This in turn
would increase the likelihood for process designers to consider LCA
as an integral part of their investigations because having access to
the information in an environment with which they are already
familiar helps to overcome the associated learning curve and information gap. Educators will be able to incorporate LCA into design
and simulation courses more readily and rapidly, thus encouraging
growth in the practice.
7. Conclusions
The energy crisis can be combatted in no small part by the
careful, considerate design of new energy conversion systems. In
particular, systems using CLC, oxyfuel, and SOFC technologies have
signicant future promise both as stand-alone power generation
systems and as important parts of complex, integrated polygeneration facilities. Key opportunities for chemical and liquid fuel
production are emerging, especially in the production of chemicals
from natural gas and shale gas to displace petroleum, the utilization of uranium for liquid fuels production, and the integration of
multiple fuel processing steps together. However, devising optimal designs for these complex systems is quite difcult, especially
when considering the entire supply chain.
Acknowledgements
This work was not funded by any organization, company, or
special interest group. I gratefully acknowledge helpful input from
Yaser Khojestah Salkuyeh, Kyle Lefebvre, Vida Meidanshahi, Jake
Nease, Jaffer Ghouse, Kushlani Wijesekera, and Leila Hoseinzadeh.
This paper is an extended version of a paper published as part of
the proceedings of the 8th International Conference on the Foundations of Computer-Aided Process Design (FOCAPD 2014) Adams
(2014).
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