04 Fakultät Energie-, Verfahrens- und Biotechnik
Permanent URI for this collectionhttps://elib.uni-stuttgart.de/handle/11682/5
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Item Open Access Process model and life cycle assessment of biorefinery concept using agricultural and industrial residues for biohydrogen production(2024) Gamero, Edgar; Ruppert, Sophia; Miehe, Robert; Sauer, AlexanderSustainable waste management strategies are urgently needed due to an increasing global population and increased waste production. In this context, biorefineries have recently emerged as a promising approach to valorize waste streams and supply a broad range of products. This study presents the process model and life cycle assessment (LCA) of a biorefinery concept using a novel biochemical method, a so-called “dark photosynthesis” conversion. This process is coupled to a photo-fermentation using microalgae. Overall, the biorefinery concept can produce hydrogen, lutein, β-carotene, and proteins for animal feed. Apple pomace from apple juice production is used as feedstock for the primary conversion step. A process model was created with the process simulation software Aspen Plus ® using experimental and literature data. Results from this model were then used in an LCA. The environmental impacts of the proposed biorefinery concept are relatively high, showing the need for process optimization in several areas. Energy system integration, stream recycling, and higher hydrogen yields are recognized as especially important for improving the environmental performance of this concept. Despite these findings, the model shows the feasibility of implementing the biochemical conversion technologies in a biorefinery concept for effectively utilizing residue streams.Item Open Access A methodology to systematically identify and characterize energy flexibility measures in industrial systems(2020) Tristán, Alejandro; Heuberger, Flurina; Sauer, AlexanderIndustrial energy flexibility enables companies to optimize their energy-associated production costs and support the energy transition towards renewable energy sources. The first step towards achieving energy flexible operation in a production facility is to identify and characterize the energy flexibility measures available in the industrial systems that comprise it. These industrial systems are both the manufacturing systems that directly execute the production tasks and the systems performing supporting tasks or tasks necessary for the operation of these manufacturing systems. Energy flexibility measures are conscious and quantifiable actions to carry out a defined change of operative state in an industrial system. This work proposes a methodology to identify and characterize the available energy flexibility measures in industrial systems regardless of the task they perform in the facility. This methodology is the basis of energy flexibility-oriented industrial energy audits, in juxtaposition with the current industrial energy audits that focus on energy efficiency. This audit will provide industrial enterprises with a qualitative and quantitative understanding of the capabilities of their industrial systems, and hence their production facilities, for energy flexible operation. The audit results facilitate a company’s decision making towards the implementation, evaluation and management of these capabilities.Item Open Access Simulation modeling for energy-flexible manufacturing : pitfalls and how to avoid them(2022) Köberlein, Jana; Bank, Lukas; Roth, Stefan; Köse, Ekrem; Kuhlmann, Timm; Prell, Bastian; Stange, Maximilian; Münnich, Marc; Flum, Dominik; Moog, Daniel; Ihlenfeldt, Steffen; Sauer, Alexander; Weigold, Matthias; Schilp, JohannesDue to the high share of industry in total electricity consumption, industrial demand-side management can make a relevant contribution to the stability of power systems. At the same time, companies get the opportunity to reduce their electricity procurement costs by taking advantage of increasingly fluctuating prices on short-term electricity markets, the provision of system services on balancing power markets, or by increasing the share of their own consumption from on-site generated renewable energy. Demand-side management requires the ability to react flexibly to the power supply situation without negatively affecting production targets. It also means that the management and operation of production must consider not only production-related parameters but also parameters of energy availability, which further increase the complexity of decision-making. Although simulation studies are a recognized tool for supporting decision-making processes in production and logistics, the simultaneous simulation of material and energy flows has so far been limited mainly to issues of energy efficiency as opposed to energy flexibility, where application-oriented experience is still limited. We assume that the consideration of energy flexibility in the simulation of manufacturing systems will amplify already known pitfalls in conducting simulation studies. Based on five representative industrial use cases, this article provides practitioners with application-oriented experiences of the coupling of energy and material flows in simulation modeling of energy-flexible manufacturing, identifies challenges in the simulation of energy-flexible production systems, and proposes approaches to face these challenges. Seven pitfalls that pose a particular challenge in simulating energy-flexible manufacturing have been identified, and possible solutions and measures for avoiding them are shown. It has been found that, among other things, consistent management of all parties involved, early clarification of energy-related, logistical, and resulting technical requirements for models and software, as well as the application of suitable methods for validation and verification are central to avoiding these pitfalls. The identification and characterization of challenges and the derivation of recommendations for coping with them can raise awareness of typical pitfalls. This paper thus helps to ensure that simulation studies of energy-flexible production systems can be carried out more efficiently in the future.Item Open Access Comparison of the temperature, radiation, and heat flux distribution of a hydrogen and a methane flame in a crucible furnace using numerical simulation(2024) Mages, Alexander; Sauer, AlexanderSustainable technologies to replace current fossil solutions are essential to meet future CO2 emission reduction targets. Therefore, this paper compares key performance indicators of a hydrogen- and a methane-flame-fired crucible furnace with computational fluid dynamics simulations at identical firing powers, aiming to fully decarbonize the process. Validated numerical models from the literature were used to compare temperatures, radiation fields, radiation parameters and heat transfer characteristics. As a result, we observed higher combustion temperatures and a 19.0% higher fuel utilization rate in the hydrogen case, indicating more efficient operating modes, which could be related to the increased radiant heat flux and temperature ranges above 1750 K. Furthermore, higher scattering of the heat flux distribution on the crucible surface could be determined indicating more uneven melt bath temperatures. Further research could focus on quantifying the total fuel consumption required for the heating up of the furnace, for which a transient numerical model could be developed.Item Open Access Effects of load forecast deviation on the specification of energy storage systems(2023) Emde, Alexander; Märkle, Lisa; Kratzer, Benedikt; Schnell, Felix; Baur, Lukas; Sauer, AlexanderThe liberalization of the German energy market has created opportunities for end-consumers, including industrial companies, to actively participate in the electricity market. By making their energy loads more flexible, consumers can generate additional income and thus save money. Energy storage systems can be utilized to achieve the required flexibility by temporarily storing excess electrical energy in the form of heat, cold, or electricity for later use. This publication focuses on how the dimensionality of energy storage is influenced by load forecasting. The results show that inaccuracies in load forecasting lead to a direct over-dimensioning and thus, a deterioration of the economics of energy storage technologies. Using two scenario cases, it shows on the one hand how important good forecasts are and on the other hand that buffers must be included in the conceptual design in order to be able to compensate for forecast errors.Item Open Access Perspectives of biogas plants as BECCS facilities : a comparative analysis of biomethane vs. biohydrogen production with carbon capture and storage or use (CCS/CCU)(2023) Full, Johannes; Hohmann, Silja; Ziehn, Sonja; Gamero, Edgar; Schließ, Tobias; Schmid, Hans-Peter; Miehe, Robert; Sauer, AlexanderThe transition to a carbon-neutral economy requires innovative solutions that reduce greenhouse gas emissions (GHG) and promote sustainable energy production. Additionally, carbon dioxide removal technologies are urgently needed. The production of biomethane or biohydrogen with carbon dioxide capture and storage are two promising BECCS approaches to achieve these goals. In this study, we compare the advantages and disadvantages of these two approaches regarding their technical, economic, and environmental performance. Our analysis shows that while both approaches have the potential to reduce GHG emissions and increase energy security, the hydrogen-production approach has several advantages, including up to five times higher carbon dioxide removal potential. However, the hydrogen bioenergy with carbon capture and storage (HyBECCS) approach also faces some challenges, such as higher capital costs, the need for additional infrastructure, and lower energy efficiency. Our results give valuable insights into the trade-offs between these two approaches. They can inform decision-makers regarding the most suitable method for reducing GHG emissions and provide renewable energy in different settings.Item Open Access Assessing the application-specific substitutability of lithium-ion battery cathode chemistries based on material criticality, performance, and price(2021) Kiemel, Steffen; Glöser-Chahoud, Simon; Waltersmann, Lara; Schutzbach, Maximilian; Sauer, Alexander; Miehe, RobertThe material use of lithium-ion batteries (LIBs) is widely discussed in public and scientific discourse. Cathodes of state-of-the-art LIBs are partially comprised of high-priced raw materials mined under alarming ecological and social circumstances. Moreover, battery manufacturers are searching for cathode chemistries that represent a trade-off between low costs and an acceptable material criticality of the comprised elements while fulfilling the performance requirements for the respective application of the LIB. This article provides an assessment of the substitutability of common LIB cathode chemistries (NMC 111, -532, -622, -811, NCA 3%, -9%, LMO, LFP, and LCO) for five major fields of application (traction batteries, stationary energy storage systems, consumer electronics, power-/garden tools, and domestic appliances). Therefore, we provide a tailored methodology for evaluating the substitutability of products or components and critically reflect on the results. Outcomes show that LFP is the preferable cathode chemistry while LCO obtains the worst rating for all fields of application under the assumptions made (as well as the weighting of the considered categories derived from an expert survey). The ranking based on the substitutability score of the other cathode chemistries varies per field of application. NMC 532, -811, -111, and LMO are named recommendable types of cathodes.Item Open Access Carbon‐negative hydrogen production : fundamentals for a techno‐economic and environmental assessment of HyBECCS approaches(2022) Full, Johannes; Ziehn, Sonja; Geller, Marcel; Miehe, Robert; Sauer, AlexanderIn order to achieve greenhouse gas neutrality, hydrogen generated from renewable sources will play an important role. Additionally, as underlined in the Sixth Assessment Report of the Intergovernmental Panel on Climate Change (IPCC), new technologies to remove greenhouse gases from the atmosphere are required on a large scale. A novel concept for hydrogen production with net negative emissions referred to as HyBECCS (Hydrogen Bioenergy with Carbon Capture and Storage) combines these two purposes in one technological approach. The HyBECCS concept combines biohydrogen production from biomass with the capture and storage of biogenic carbon dioxide. Various technology combinations of HyBECCS processes are possible, whose ecological effects and economic viability need to be analyzed in order to provide a basis for comparison and decision‐making. This paper presents fundamentals for the techno‐economic and environmental evaluation of HyBECCS approaches. Transferable frameworks on system boundaries as well as emission, cost, and revenue streams are defined and specifics for the application of existing assessment methods are elaborated. In addition, peculiarities concerning the HyBECCS approach with respect to political regulatory measures and interrelationships between economics and ecology are outlined. Based on these considerations, two key performance indicators (KPIs) are established, referred to as levelized cost of carbon‐negative hydrogen (LCCNH) and of negative emissions (LCNE). Both KPIs allow deciding whether a specific HyBECCS project is economically viable and allows its comparison with different hydrogen, energy provision, or negative emission technologies (NETs).Item Open Access Numerical investigation and simulation of hydrogen blending into natural gas combustion(2024) Jung, Laura; Mages, Alexander; Sauer, AlexanderThis study reviews existing simulation models and describes a selected model for analysing combustion dynamics in hydrogen and natural gas mixtures, specifically within non-ferrous melting furnaces. The primary objectives are to compare the combustion characteristics of these two energy carriers and assess the impact of hydrogen integration on furnace operation and efficiency. Using computational fluid dynamics (CFD) simulations, incorporating actual furnace geometries and a detailed combustion and NOx emission prediction model, this research aims to accurately quantify the effects of hydrogen blending. Experimental tests on furnaces using only natural gas confirmed the validity of these simulations. By providing precise predictions for temperature distribution and NOx emissions, this approach reduces the need for extensive laboratory testing, facilitates broader exploration of design modifications, accelerates the design process, and ultimately lowers product development costs.Item Open Access Identifying and dealing with interdependencies and conflicts between goals in manufacturing companies’ sustainability measures(2024) Koch, David; Sauer, AlexanderCompanies are increasingly focusing on sustainable business practices. Internal and external stakeholders’ expectations manifest in legal requirements, national and international standards, and market and customer expectations, among other things, must be considered. In addition to profit maximization, which is the usual target for corporate management, management must consider environmental sustainability aspects such as resource efficiency, greenhouse gas intensity, and a company’s emissions behavior. In addition, social aspects related to the company’s employees, the immediate urban environment, the situation in the supply chain, and effects on the market environment must increasingly be considered. Specifically, companies are faced with the challenge of dealing with conflicting objectives regarding the various aspects of sustainability and, if necessary, weighing them up against each other. These trade-offs must be made against the company’s socio-economic and ecological environment, corporate strategy, and sustainability goals. This paper provides an overview of current approaches and research gaps on this topic through a literature review. It highlights the lack of methods and frameworks to specifically deal with trade-offs and conflicts between goals.
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