ENERGY HIGHLIGHTS - No16 2021 - NATO ENERGY SECURITY CENTRE OF EXCELLENCE
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ERGY SEC EN U O T RI NA NATO ENERGY SECURITY TY CENTRE OF EXCELLENCE CE CE TR N E N EO LL F E XC E ENERGY HIGHLIGHTS No 16 2021 ENERGY H IG HLIG HTS No 16 1
This is a product of the NATO Energy Security Centre of Excellence (NATO ENSEC COE). It is produced for NATO, NATO member countries, NATO partners, related private and public institutions and related individuals. It does not represent the opinions or policies of NATO or NATO ENSEC COE. The views presented in the articles are those of the authors alone. © All rights reserved by the NATO ENSEC COE. Articles may not be copied, reproduced, distributed or publicly displayed without reference to the NATO ENSEC COE and the respective publication. 2 No 16 ENERGY H IG HLIG HTS
Content 4 Editorial 5 Nitrogen based propellants as substitute for carbon containing fuels BY DR. JUTTA LAUF, WSEWOLOD RUSOW, DR. REINER ZIMMERMANN 22 The hidden costs of solar photovoltaic power BY THOMAS A. TROSZAK 34 What to expect from an energy transition for Australia’s energy security and its Defence Force? BY CAMILLE FOURMEAU, NICOLAS MAZZUCCHI, REINER ZIMMERMANN 44 The Synchronization of the Baltic States’: Geopolitical Implications on the Baltic Sea Region and Beyond BY JUSTINAS JUOZAITIS ENERGY H IG HLIG HTS No 16 3
Editorial By COL Romualdas Petkevičius (LTU-AF) Director of the NATO ENSEC COE T he clean energy Meanwhile, in his piece Thomas Troszak exam- transition is with- ines the environmental impact of solar photo- out a doubt one voltaics (PV) production. More specifically, the of the greatest author introduces the readers to the many types challenges of the 21st cen- of fossil fuels that are used in PV production and tury. The reasons for that notes how some other environmentally hazard- are myriad, complex and ous inputs are required before the delivery of a sometimes overlapping. solar PV array can take place. There are significant chal- lenges associated with In the third article, Camille Fourmeau, Nicolas some of the new and innovative energy tech- Mazzucchi and Dr. Reiner Zimmermann analyse nologies that could help to decarbonise hard-to- Australia’s energy transition challenges and its abate sectors. And, due to a number of reasons, implications for the country’s military. The au- even some of the more established technologies thors place particular emphasis on the difficulties have flaws that often are easily overlooked. Canberra faces while trying to reconcile its cur- rent dependency on fossil fuels, the negative im- In addition to these technological problems, in plications of climate change and the urgent need some countries historical path dependencies can to expand investments in renewable sources of hinder the clean energy transition from gaining energy. momentum. Or, alternatively, traditional energy security issues may at times divert some of the Finally, Justinas Juozaitis explains why it is attention that could otherwise be spent on mak- important for the Baltic States to disconnect ing the energy systems greener. their power systems from the Soviet-era BRELL power grid and to synchronize with the Con- This issue of Energy Highlights will tackle some tinental European Network. The author not of these challenges head on. only provides a comprehensive account of the historical development of the BRELL grid, In their contribution, Dr. Jutta Lauf, Wsewolod highlights the synchronization significance for Rusow and Dr. Reiner Zimmermann examine the Baltic energy security, but also points out how utility of nitrogen-based fuels. They argue that Russia and Belarus have been pursuing various these fuels have significant advantages over car- strategies to deter the Baltics from leaving the bon-based fuels because they do not emit green- BRELL grid. house gases or any other hazardous compounds during combustion. While the authors agree that In the end, we hope that these articles would it may take a while before nitrogen-based fu- provide you, the readers, not only with a better els can become adopted on a wider scale, they grasp of the clean energy transition challenges are confident that in the near future these fuels that many governments face, but would also in- could play a meaningful role in the global decar- spire you to be part of the change. bonisation effort. 4 No 16 ENERGY H IG HLIG HTS
Nitrogen based propellants as substitute for carbon containing fuels by Dr. Jutta Lauf, Wsewolod Rusow and Dr. Reiner Zimmermann 1. ABSTRACT N itrogen based fuels have several ad- and plants are existing in all major agricultural vantages over carbon-based fuels. No countries, the upscaling of ammonia production greenhouse gases (GHG) or health seems easily possible. The prime advantage of ni- compromising compounds are emit- trogen based fuels are both, the intrinsic lack of ted during the combustion and the subsequent carbon as well as the technological maturity of waste gas treatment of most nitrogen bases their production, transport and storage. As the fuels. When nitrogen based fuels are produced various propulsion engines and the combustion with power from renewable sources, no GHG technologies reach technical maturity, nitrogen are emitted during the production process either. based fuels will certainly become attractive for a All nitrogen based fuels originate from ammonia decarbonizing world. (NH3), which is produced via the Haber-Bosch- Process. Ammonia combustion engines have 2. INTRODUCTION been developed and tested as prototypes for sev- eral decades. In recent years the interest mainly Nitrogen based fuels are well known since several for use in naval propulsion systems has grown. decades but rarely used for transportation pur- Marketable fuels cells using ammonia are now poses. Their inherent environmental advantage commercially available, as well as fuel cells using is the absence of any carbon dioxide (CO2) emis- hydrogen which was stripped from the ammonia. sions during combustion. Therefore, they may Hydrazine is a commonly used rocket propellant contribute significantly to the internationally but is not used in civil environments due to its demanded decarbonisation of the transport sec- high toxicity. Ammonium nitrate and urea en- tor. However, easy access to fossil carbon-based gines are fringe applications which were currently gas (methane) and liquid fuels (derived from tested in laboratory environments. Production of crude oil) during the past decades as well as their nitrogen based fuels by using renewable power cheapness, low safety risks and established pro- sources would be most economically feasible cessing infrastructure made them the almost ex- with energy produced in the global Sunbelt. Since clusive propulsion energy for transportation pur- the necessary Haber-Bosch technology is mature poses. Crude oil is easily refined to e. g. kerosene, by Dr. Jutta Lauf, Wsewolod Rusow and Dr. Reiner Zimmermann Dr. Jutta Lauf works at the department of Renewable Energy Management at the University of Applied Sciences Erfurt. She is also a Fellow at the NATO ENSEC COE. Wsewolod Rusow works at the Doctrine and Concept Development Division of the NATO ENSEC COE. Dr. Reiner Zimmermann was the Head of the Research and Lessons Learned Division of the NATO ENSEC COE. ENERGY H IG HLIG HTS No 16 5
diesel, or gasoline. In the next decade the need actions were taken to reduce the dependency to move away from fossil carbon-based energy from fossil carbon fuels in the transportation or may favour – at least in part - nitrogen as fuel in heating sectors on a global scale and only the nu- the transportation sector due to its ecologic ad- clear power generation sector gained importance vantages, the technological practicability and the since the end of the 1970ies, mainly in techno- relatively moderate changes needed to existing logically advanced countries (Roser 2020). infrastructure for production and logistics. Even today most attempts to reduce or mini- As early as 1943, during the fossil fuel shortages mise the usage of carbon-based fossil fuels are in WW II, a retrofitted bus engine was propelled not price driven. In fact, global oil prices have by ammonia (NH3) in Belgium (Kroch 1945) (Fig- reached a relatively stable minimum caused by ure 1). In the 1950ies an Austrian inventor rede- the increased application of fracking techniques signed a motor bike to run on hydrazine (N2H4) in North America, political discord of the oil in a fuel cell (Figure 2). Hydrazine in combina- producing countries about production quanti- tion with other fuels was used during WW II as ties and the current economic slow-down due a propellant for the German A4 rocket and the to the SARS-CoV-2 pandemic (BP 2020; BBC rocket engine driven German Me-163 interceptor 09.06.2020). Current attempts to reduce the us- airplane (Ziegler 1976). Hydrazine is still com- age of fossil fuels and to replace them with carbon mon in the Titan and Ariane rockets as well as in free fuels are due to mounting concerns regarding satellites and space ships (Haidn 2008). However the negative environmental consequences of ris- hydrazine is not widely used because of its high ing global temperatures which are caused by the toxicity (Table 1) (Bundesanstalt für Arbeitss- increasing atmospheric concentration of CO2 and chutz und Arbeitsmedizin 1991). Nitrous oxide other greenhouse gases. The increasing global (N2O) injection in piston driven engines was used temperatures cause rising sea levels, more se- by high performance airplanes during WWII as an vere droughts, raging wildfires and the melting of additional power booster. permafrost areas. The resulting natural disasters, economic disruptions, social unrest and mass Non-fossil originated carbon-based fuels (often migrations will result in more refugee and rescue called “synthetic carbon fuels”) are very expen- missions for the military forces (Reinhardt and sive in production and are currently used for niche Toffel 2017; Fourmeau and Zimmerman 2020). applications only. Even after the global oil price shocks in 1973 and 1979/80, which were caused The present article will provide an overview of by geo-political disruptions (BP 2020), no serious the chemical production processes of nitrogen- based fuels using power from renewable energy sources as well as cover the safety issues of nitro- gen fuels in comparison with carbon-based fuels. Also, propulsion technologies for nitrogen based fuels and possible global NH3 production capaci- ties will be discussed. 3. NITROGEN BASED FUELS IN POWER-TO-FUEL PROCESSES Power–to-fuel (PtF) is an umbrella term for pro- cesses using electricity from renewable sources for the production of gaseous or liquid fuels. Liq- uid fuels are the most attractive and cost-effec- tive approach for storing and delivering energy Figure 1: Retrofitted bus with an ammonia driven for large scale applications. They are unmatched internal combustion engine in 1943 during WWII in in terms of transportability and energy density Belgium (Kroch 1945). 6 No 16 ENERGY H IG HLIG HTS
(Andersson and Grönkvist 2019) compared with quires a significant amount of energy and safety gaseous fuels (Table 1). precautions to reach these states (Table 1) (An- dersson and Grönkvist 2019). H2 is also a valua- Liquid fuels come with higher production costs ble base chemical, leading to further applications compared to gaseous fuels because more steps in fuel syntheses. are required to produce them. Due to the second law of thermodynamics each energy conversion (1) Electricity production from renewable sourc- process – of which chemical synthesis is one - re- es. Electricity can be used directly in electric en- sults in a loss of energy available to perform work gines. (2) Electrolysis of water and production of (free energy). This fact leads with each additional hydrogen (H2). (3) Synthetic gas (syngas) or am- step of synthesis to substantial losses in the monia (NH3) can be produced with H2. Syngas useable fuel energy content (Atkins et al. 1990; requires a CO2 source from fossil or non-fossil Perner et al. 2018). Consequently, the number of sources. NH3 requires nitrogen (N2) from ambi- production or energy conversion steps should al- ent air. (4) Reactors for the synthesis of organic ways be kept as low as possible. compounds (synthetic fuels or methanol) or hy- drazine. (6) Fuel cell for electricity production. (7) A selection of production pathways for nitrogen- Engine technologies useable for different types based fuels is presented in Figure 2 . All processes of fuels. Electricity from the producing plants can start with the production of electricity from re- be used directly in electric engines. H2, NH3 and newable sources (1). Electricity can be directly hydrazine can be either used in fuels cells, which used in electric engines via battery storage. power electric engines or in internal combustion Electricity driven electrolysers produce hydro- and rocket engines. Modified after (Sterner 2019; gen (H2), from water, which is the first possible Perner et al. 2018; Grinberg Dana et al. 2016). chemical storage (Holleman et al. 1985). H2 is a nontoxic gas under normal conditions, but han- NH3 produced by the Haber-Bosch process (Hol- dling is difficult due to its flammable and ex- leman et al. 1985) is the first of several possible plosive properties (Table 1) (Bundesanstalt für nitrogen based fuels (3). Nitrogen (N2) is needed Arbeitsschutz und Arbeitsmedizin 2020). The as a base component (Formula 1) and normally volumetric and gravimetric energy density of H2 extracted from ambient air. NH3 can be used as in compressed or liquefied form is high but it re- a base chemical for further synthesis (4), in fuel cells (6) or in internal combustion or jet engines (7). Hydrazine and its methyl derivatives are used as long term storable rocket fuels (Haidn 2008). Because hydrazine is extremely toxic (Bundesan- stalt für Arbeitsschutz und Arbeitsmedizin 1991) (Table 1), its usage is only allowed in environ- ments where no substitutes are possible, e.g. in military and space technologies. Fuels which are based on nitrates (NO3-) - including aqueous so- lutions of urea, ammonium nitrate and their mix- tures - are currently tested in laboratory environ- ments (Grinberg Dana et al. 2016). Carbon based fuels (often simply called synthetic fuels) derived from the Fischer-Tropsch pro- cess or methanol from methanol synthesis can be obtained via the production of synthetic gas Figure 2: Schematic of power- to-X (PtX) produc- (syngas) (Holleman et al. 1985). These chemical tion pathways and the usage of the products for processes require CO2 as the carbon source. Non mobility. fossil CO2 sources (secondary carbon sources) as ENERGY H IG HLIG HTS No 16 7
well as their production costs were discussed in mans to leave a contaminated area before health (Lauf 2020b). Methanol can be used in fuel cells risks occur. However, if suddenly exposed to high and methanol or synthetic fuels can also be used concentrations, the human nose can no longer in internal combustion and jet engines. detect it. Hydrazine is the most toxic and inflam- mable of the fuels discussed. Ammonia is 200 Ammonia and hydrazine are generally more toxic times less toxic than hydrazine and not inflam- than conventional fossil or synthetic fuels (Table mable. The smell of hydrazine is similar to that of 1). Many countries define maximum workplace NH3, but less intense. Ammonium nitrate is not air concentrations for mean daily exposure to toxic but explosive in solid state while urea is nei- humans (e.g for Germany: Bundesanstalt für Ar- ther toxic nor inflammable. beitsschutz und Arbeitsmedizin 1991; Bundesan- stalt für Arbeitsschutz und Arbeitsmedizin 2020). The carbon-based methanol and diesel fuels are Hydrogen as the first fuel generated from elec- less toxic than NH3 but inflammable. A maxi- tricity is not toxic but extremely inflammable mum workplace air concentration for diesel is and explosive. It is odourless and can only be de- not given, as it is a mixture of many components. tected by elaborate technical devices. NH3 is also The most toxic component is benzene. Synthetic toxic but self-alarming due its pungent smell. diesel may differ from its fossil counterpart, as The limit of detection (LOD) by the human nose the Fischer-Tropsch synthesis can be managed to is about 4 times lower than the allowed work- result in less toxic by-products. place air concentration (Assumpção et al. 2014). The unpleasant smell of NH3 normally forces hu- The so-called inferior heating values or net ca- Maximum workplace Inflammable Energy content, Hi air concentration and/or explosive [kWh/kg] [ppm] Hydrogen (g) (H2) - (1) Yes (3) 33,3 (6) Ammonia (g) (NH3) 20 (1) No (3) 5,2 (6) Hydrazine (l) (N2H4) 0.1 (2) Yes (3) 5,5 (6) Urea (s) (H2NCONH2) - (1) No (3, 4) 2,6 (6) Ammonium nitrate (NH4NO3) - Solid - (1) Yes (5) - - Aqueous solution - (1) No (5) - Methanol (l) (CH3OH) 100 (1) Yes (4) 6,3 (6) Ethanol (l) (CH3-CH2OH) 200 (1) Yes (4) 7,5 (6) Diesel fuel (l) (analogue to F-34) - (1) Yes (1) 11,8 (7) Carbon dioxide (g) (CO2) 5 000 (1) No - Table 1: Maximum workplace air concentrations in parts per million [ppm], flammability and energy densi- ty for selected alternative fuels as well as for ethanol and carbon dioxide. State of aggregation at ambient air temperature and pressure: g = gaseous, l = liquid, s = solid). Energy content expressed as the so called inferior heating value (net caloric value, Hi) Citations: (1) (Bundesanstalt für Arbeitsschutz und Arbeits- medizin 2020); (2) (Bundesanstalt für Arbeitsschutz und Arbeitsmedizin 1991); (3) (Holleman et al. 1985); (4) (Beyer and Walter 1988); (5) (Grinberg Dana et al. 2016); (6) (Beilicke 2010); (7) (Reitmair 2013). 8 No 16 ENERGY H IG HLIG HTS
loric value Hi of a selection of fuels (referenced to Large scale electrochemical storage in batteries weight) are shown in Table 1. H2 shows the highest is not yet economic and affordable, although a Hi value. The nitrogen-based fuels NH3 and N2H4 as pilot project in Australia shows promising results well as methanol and ethanol show inferior heating in levelling fluctuations and peaks in the elec- values within the same order of magnitude. Hi is tricity demand during the summer months for a rising with the increasing number of chemical bonds community of 30 000 households (DER SPIEGEL of the respective compound. The energy content 2017). Physical storage using pumped hydro of diesel fuel is highest, as it contains much more power stations is a mature technology but lim- chemical bonds. From the perspective of Hi values, ited by topographic conditions. Environmental diesel appears to be the most promising fuel to pro- and social problems invoked in building them are duce. However, the Hi does not reflect the amount paramount and have led to an almost complete of energy needed – or, in other words, the amount construction freeze during the past decades in of free energy lost - to produce these components the western world (Sinn 2017; Bundesministe- from steps (3) to (5) in Figure 2. If the energy con- rium der Justiz und für Verbraucherschutz 2020). tent of the product and the energy needed for its Chemical storage of electricity is currently in- synthesis are accounted for, H2 is the best fuel to tensely studied. It is the preferred storage solu- use and NH3 is the second best. tion because the energy carrier can be directly re- transformed into electricity by fuel cells, internal FLUCTUATING POWER SUPPLY FROM combustion engines, jet engines etc or used as RENEWABLE PLANTS AND STORAGE OF fuel for mobility. ELECTRIC ENERGY The focus of the following sections is on the pro- Electricity is difficult to store on a large scale. It duction steps of nitrogen based fuels from re- has to be provided “on time” to enable efficient newable electric power, in comparison with car- and effective processes in all sectors of society. bon bases fuels. Most providers ensure this flexibility by provid- ing excess production capacity in plants with in- 4. INDUSTRIAL SCALE PRODUCTION OF herent ultralow response times (e.g. gas powered NITROGEN-BASED FUELS plants). Power from renewable sources usually can’t be managed in this way as it has to be pro- AMMONIA duced when e.g. the wind blows or the sun shines. Ammonia is a poisonous (Table 1), colourless Therefore, the key enablers for the shift to re- and lighter-than-air gas with a characteristic newable energy sources are efficient means of pungent smell. Its synthesis (artificial nitrogen storing renewable electricity for times when it is fixation) from atmospheric nitrogen (N2) and not generated and distributing the stored energy hydrogen (H2) was invented before WWI by the effectively over large distances. Hydro powered German scientists Fritz Haber and Carl Bosch. dams and biogas plants are the only renewable The so called Haber-Bosch process was imple- energy producing technologies which are adjust- mented at an industrial scale during WWI (Hol- able to fluctuating electricity demands. Howev- leman et al. 1985) and provided the German er, they are not available on a scale needed for Empire with nitrate (NO3-) which could not be many industrial processes. obtain from the mines in Chile as they were con- trolled by the Allied forces. Nitrate was needed Three forms of storage are considered in this arti- for the production of explosives like nitroglyc- cle: a) batteries, b) physical storage and c) chemi- erine and dynamite. Since more than 100 years cal storage. This scheme is not the conventional the Haber-Bosch process remains virtually un- classification of physics and chemistry. Energy in changed and this mature technology provides batteries is stored due to electrochemical process- NH3 at low costs. Nowadays about 70 % of the es. Physical storage in this article means gravita- global ammonia production of about 11,3 * 109 t tional, kinetic and thermal energy. Chemical stor- in 2014 is used for fertilizer production (Ritchie age means the synthesis of new compounds where and Roser 2020). the energy is stored in chemical bonds. ENERGY H IG HLIG HTS No 16 9
The chemical reaction is performed using cat- sodium salt of hypochloric acid (NaClO) is used as alysators at >10 MPa pressure and temperatures oxidant for NH3 (Holleman et al. 1985). between 400 – 500 °C (Holleman et al. 1985). NH3 + ClO- NH2Cl + OH- (4) 91.8 kJ + 3 H2 + N2 2 NH3 (1) NH2Cl + NH3 + OH- N2H4 + Cl- + OH- (5) Currently about 90% of the hydrogen needed for the process is obtained via synthetic gas by steam gas reformation of fossil resources (typi- AMMONIUM NITRATE cally gas or coal) which releases huge amounts of Ammonium nitrate (NH4NO3) is globally pro- CO2 (Holleman et al. 1985). duced in large quantities as a raw material for most common nitrogen fertilizers. It is produced in two steps: Nitric acid (HNO3) production from 206.2 kJ + CH4 + H2O CO + 3 H2 (2) NH3 and subsequently NH4NO3 production from nitric acid. Both steps are often performed at the same industrial site. The production and handling Hydrogen can also be obtained by the expensive of NH4NO3 involves mature technologies. process of electrolysis of water (Holleman et al. 1985) which requires large amounts of electric Ammonia as a gas (g) from the Haber-Bosch pro- energy (Lauf 2020a). cess is oxidised with oxygen (g) in the presence of platinum/rhodium catalysts in solid state (s) to nitric acid (HNO3) which is dissolved in the water 286.02 kJ + H2O (liquid) H2 + ½ O2 (3) formed during the reaction and which results in an aqueous solution (aq). This process is called Ostwald process. Industrial sized Haber-Bosch plants have their own on-site N2 supply, which is obtained from ambient air (78% N2, 21% O2 and other gases). 2 NH3 (g) + 4 O2 (g) + H2O (l) In steam gas reforming plants, the ambient air 2 HNO3 (aq) + 3 H2O (g) + 740 kJ (6) is used in the clean-up of the synthetic gas (For- mula 1) resulting in a pure N2 gas. In electrolyser plants, pure N2 gas can be generated either by Ammonium nitrate is produced by the acid-base cryogenic distillation of liquified air or by mem- reaction of NH3 in aqueous solution and HNO3 in brane filtered compressed ambient air. The lat- aqueous solution. The dissolved salt is then dried ter is less expensive and delivers lower, but suf- and handled in solid state. ficient, N2 purity grades. (Holleman et al. 1985; thyssenkrupp Industrial Solutions AG 2020) NH3 + HNO3 NH4NO3 (7) HYDRAZINE Hydrazine is a toxic and carcinogenic oily liquid. Its smell resembles that of NH3. For safety reasons it is Ammonium nitrate is explosive and therefore mostly used in the form of hydrazine hydrate which widely used in mining and quarrying. As fertilizer is unstable and even as in aqueous solution danger- it is mixed with lime (calcium carbonate, CaCO3) ous to handle. At industrial scale three pathways and oil to prevent its explosive properties (Holle- for hydrazine (N2H4) are in common use which all man et al. 1985). However, several catastrophic use NH3 as base chemical. The most common path- accidents have occurred ever since the Haber- way is the two step Raschig synthesis in which the Bosch- and Ostwald processes were first estab- 10 No 16 ENERGY H IG HLIG HTS
2 NH3 + CO2 H2NCONH2 + H2O (8) 5. WASTE GAS PROPERTIES AND APPLICA- TIONS OF NITROGEN-BASED FUELS The composition of waste gases are defined by the energy conversion technology used. Waste gases from fuel cells contain only the products of a complete combustion with no side products. In the case of carbon-based fuels these are carbon di- Figure 3: Aerial photo of the BASF Oppenau/Lud- oxide (CO2) and water (H2O) in the case of ammo- wigshafen (Germany) production plant after the nia- and nitrate-based fuels these are N2 and H2O. devastating explosion of 400 tonnes of ammoni- The waste gases of urea contain CO2, N2 and H2O. um sulphate nitrate in 1921 causing 559 fatalities (Abelshauser 2003). The crater in the foreground Fossil fuels do contain varying amounts of sul- indicates the location of the storage area where the explosion happened. phur. The maximum sulphur concentration of fu- els is often regulated by local laws. Sulphur burns into a mixture of sulphur oxides (SOx). In carbon- lished in Germany on an industrial scale. In 1921 based fuels volatile organic compounds (VOC’s) at the BASF Oppenau/Ludwigshafen manufac- and particulate matter (PM) are formed during turing plant in Germany approx. 400 tonnes of incomplete combustion. Depending on the com- stored ammonium sulphate nitrate exploded and bustion temperature, the nitrogen (N2) and oxy- killed 559 persons, mostly workers of the plant gen (O2) from the air form a mixture of nitrogen (Figure 3) (Abelshauser 2003). The most recent oxides (NOx). This process occurs for both, car- explosion occurred in 2020 in Beirut (Lebanon), bon- and nitrogen-based fuels and sparked an in- when approx. 2750 tonnes of stored ammonium tense environmental debate over the future use nitrate exploded in a warehouse at the harbour of diesel engines. In nitrogen based fuels nitrous (BBC 05.08.2020). oxide (N2O) and NOx may form as products of an incomplete fuel combustion.(Baird 1995; Holle- UREA man et al. 1985; Pavlos and Rahat 2020) Pure urea is a non-toxic and non-explosive crystal- line solid which easily dissolves in water or alco- AMMONIA hols. It is used as fertilizer in agriculture and for the The complete combustion of ammonia under reduction of NOx in power plants and combus- laboratory conditions is shown in Formula 9. No tion engines. Sold under the trademark “AdBlue” greenhouse gases (CO2, N2O, NOx) and no toxic it contains one third of urea mixed with water. components (NOx, SOx, VOC’s and PM) are re- Other applications are as a pharmaceutical for the leased to the atmosphere (Holleman et al. 1985). treatment of skin diseases. The production of urea at an industrial scale became possible after the Haber-Bosch process was established. Carl Bosch 4 NH3 + 3 O2 2 N2 + 6 H2O + 1 267 kJ (9) and Wilhelm Meiser established an urea produc- tion site in 1922 (Holleman et al. 1985). A selection of ready to use solutions as well as de- For urea production NH3 and CO2 are mixed at velopment projects in early and advanced stages temperatures of 170 – 220 °C and at pressures with emphasis on NATO members and partners is between 12.5 – 25.0 * 106 Pa (125 – 220 bar). The given below. Intensive research and development reaction is in equilibrium and can be pushed to- work in this field is also done by the Peoples Re- wards the desired urea product by adding NH3 in public of China, the Republic of Korea and Japan. excess (Holleman et al. 1985). ENERGY H IG HLIG HTS No 16 11
Ammonia in NH3-fuel cells diesel engines retrofitted in commercially avail- Fuel cells provide optimal combustion conditions able cars and trucks to run on pure NH3, as well with no secondary reactions. However, NH3-fuel as standard carbon-based fuels mixed with NH3. cells are not yet a mature technology and re- Prototype cars and trucks are operating (Vezina search and development efforts are being under- 2020). Ammonia is also tested under laboratory taken on a global scale (Assumpção et al. 2014; conditions as sole fuel in internal combustion en- Cinti et al. 2016; Holleman et al. 1985).Currently gines in the shipping sector by the Finnish ship- a pilot project which is partly financed by the EU ping company Wärtsilä. Results are not available Horizon 2020 SHIPFC program is upscaling a 100 yet, but first tests seem promising (Figure 4 a) kW NH3-fuel cell to a 2 000 kW version. It will (Wärtsilä Helsinki Campus 2020). The German be installed the long haul vessel “Viking Energy”, engineering company MAN has already devel- allowing emission free sailing for 3 000 hours an- oped a NH3 driven internal combustion engine nually. The system should be operative on the and is currently building cooperations with ship- vessel by the end of 2023. The NH3 needed will yard companies for its implementation (Figure 4 be produced by electrolysis.(SHIPFC 2020) b). (MAN Energy Solutions 2019) Ammonia in H2-fuel cells While NH3 as fuel shows no CO2, PM, VOC’s or SOx emissions, other emissions from unburnt Ammonia is also useable in H2-fuel cells. The NH3 NH3, N2O and NOx are significant. Therefore is catalytically split into N2 and H2. The N2 is re- post treatment technologies for cleaning these leased directly into the air while the H2 is fed into exhaust gases are needed. Mature technologies the fuel cell. No secondary products are formed. like selective catalytic reduction, SCRare avail- Such H2-fuel cells systems powered by NH3 can able (MAN Energy Solutions 2019; Pavlos and be purchased for private sector applications Rahat 2020). (GENCELL, Israel). They provide uninterruptable power supply (UPS) for critical infrastructure Ammonia and diesel in dual fuel internal i. e. hospitals or main power supply for remote combustion engines communities or remote telecommunications infrastructure(GENCELL WORLDWILD 2020). In recent years the diesel engine has received a great deal of scrutiny with respect to NOx and Ammonia in internal combustion engines PM emissions. Emission treatment systems (i. e. AdBlue injection) are now widely available to A Canadian inventor showed the feasibility of Figure 4: A)Test engine for using NH3 as fuel in an internal combustion engine in a laboratory at the Wärt- silä Helsinki Campus of the Wärtsilä Corporation (Finland) (Wärtsilä Helsinki Campus 2020). B) Engine test room at MAN Energy Solutions (The Maritime Executive 2020) 12 No 16 ENERGY H IG HLIG HTS
minimise these emissions and became standard thus requiring no external ignition devices or in many truck engines. With respect to the decar- chemicals. Hydrazine based liquid fuels are e. g. bonisation of the economy, dual fuels of NH3 and Aerozin 50 used in the USA built Titan rockets lower auto-ignition temperature fuels like die- and UH 25 used in the European Ariane rocket. It sel fuels are in early testing phases. Preliminary is estimated that currently about 500 satellites results show that conventional diesel engines in orbit use hydrazine based small control rockets can use NH3/diesel mixtures but produce high for position and orbit control. In the NASA Space amounts of NH3 and NOx emissions. Adjust- Shuttles missions, the high toxicity of hydrazine ments on the injection system may reduce the required careful pre-launch and post-touchdown emissions, but the implementation of an after- checks for N2H4 leaks by teams wearing protec- treatment system is required to meet emission tive gear and self-contained breathing equipment standards.(Pavlos and Rahat 2020) (Jenkins 2016). Ammonia in new settings Many naval forces currently use hydrazine in their Ammonia as carrier for H2 is a versatile agent for submarine rescue systems for emergency sur- innovative energy solutions. The decomposition facing by rapid displacement of the ballast tank of NH3 into N2 and H2 is a well-known process water upon injection. The RESUS (REscue system (see above, NH3 in H2 fuel cells). The H2 gained for SUbmarineS) uses hydrazine which catalyti- may be used either in pure H2 combustion en- cally decomposes in the ballast tanks and creates gines or in dual fuel (H2/diesel) combustion en- buoyance. (ArianeGroup 2020) gines (Wang et al. 2013). NITRATE AND UREA-BASED FUELS HYDRAZINE Nitrate-based fuels burn under optimal laborato- As early as in May of 1944 the German Luftwaffe ry conditions without releasing CO2, VOC, PM or put a rocket engine powered interceptor aircraft NOx. Urea-based fuels do not release NOx under into active service. The Messerschmitt Me-163 optimal laboratory conditions but always release “Komet” used a volatile fuel mixture of T-Stoff CO2. (Grinberg Dana et al. 2014; Grinberg Dana (80% hydrogen peroxide and 20% water) and C- et al. 2016). Whether this can be also achieved Stoff (hydrazine hydrate, methyl alcohol and wa- in service engines has not been tested yet. A fuel ter), which provided a maximum thrust of 1 500 infrastructure is not existing but ammonium kp (3 300 lb.). The airplane set the speed record nitrate could be transported as non-toxic sub- for its time at 1 170 km/h or 700 mph. A surviving stance in solid state or in aqueous solutions. The airplane is on display in at the Smithsonian’s Boe- solid state – when handled properly – is also non- ing Aviation Hangar at the Steven F. Udvar-Hazy explosive. However, accidents occur on a regular Center in Chantilly, VA (USA) (National Air and basis (c.f. Fig 3). Space Museum 2021). The first operational mili- tary use of hydrazine as rocket propellant was in 6. AMMONIA COMBUSTION IN INTERNAL the German A4 ballistic long range artillery rock- COMBUSTION ENGINES FROM AN ets (also known as V-2) which were launched in ENGINEERING POINT OF VIEW late 1944. The same A4 type rocket started suc- If the question is the feasibility of using ammo- cessfully from the deck of a US aircraft carrier in nia in internal combustion engines there is only 1947 initiating the era of seaborne rocket launch- one simple answer: yes, an internal combustion es. (Zaloga 2003). engine can be driven with either ammonia or its mixtures. This answer remains valid for Compres- Hydrazine (pure or in mixture with e. g. dimethyl sion-Ignition Engines (CIE) and Spark-Ignition En- hydrazine) is a very commonly used liquid rocket gines (SIE) likewise. A gas turbine can be “fired” fuel. It ignites as a hypergolic fuel (self-igniting with ammonia blends as well. This has been fuel mixture) if brought in contact with an oxi- proven several times through basic research, dizer like dinitrogen tetroxide (NO2 N2O4) feasibility studies, experiments and prototypes. ENERGY H IG HLIG HTS No 16 13
Nevertheless, the challenge is not to offer a new compression ratios as much as 35:1 are needed propulsion technology to the public or markets, for ammonia as fuel in CI-engines (Kong and Re- it rather is to suggest a new propulsion technol- iter 2011). Therefore, the use of a pilot fuel is re- ogy which can replace the existing technology. quired in order to achieve and maintain a certain ignition temperature and compression ratio. Very In the following, the focus is more on feasibil- common and useful pilot fuels are diesel or Di- ity and less on economic competition, which is methyl Ether (DME) – a synthetic substitute for discussed separately. While it is not very diffi- diesel fuel. Fuels with higher cetane numbers cult to replace passenger cars after a couple of show generally better ignition characteristics years of service it is more difficult to modify a with ammonia (Pearsall and Garabedian 1967). fleet of hundreds of container freighters where An ammonia content up to 95% was feasible with the life cycle of the asset is 25 years and more. only 5% diesel fuel when used in a John Deere en- The logical solution is a dual use technology that gine. However, the optimal mixture is 40% diesel provides a sufficient transition period for the new with 60% ammonia since a diesel amount larger technology with a minimum of drawbacks on the than that would limit the ammonia´s flammabil- overall performance. A dual use technology in ity (Reiter and S.-C. Kong 2008). Due to the DME this context means that either one or the other chemical characteristics it can be mixed directly fuel is used for combustion. No mixtures of fuels with liquid ammonia and injected into a CI en- are used. gine. Researchers at the Iowa State University (USA) demonstrated this in 2013 when they suc- COMPRESSION-IGNITION ENGINES (CIE) cessfully used it in an off-the-shelf diesel engine. Ammonia is flammable, but the ignition temper- ature is higher than for petroleum-based fuels. The original setup used for the exploration of Thus, it is not possible to use ammonia as a sole highly advanced liquid ammonia direct injection fuel in a CI-engine due to the high compression was designed very similar to a diesel direct injec- ratios needed for ignition/combustion (Pearsall tion system. A fuel combination of ammonia and and Garabedian 1967; Brohi 2014). Very high DME was directly injected into the engine, using C-RIO Fuel Controller C-RIO Engine Controller Computer Ocilloscope Charge amplifier Common-Rail High Pressure Fuel pump Smoke meter Mixing Fuel Tank 5 Gas Analyzer NOx/NH3 Analyzer Injector Pressure Sensor Ammonia DME Intake Air Flow Measurement N2 Exhaust Out Intake Air Heating control Encoder Laminar Flow Intake Air In Dynamometer Diesel engine Meter Surge Tank Speed and Torque signal Figure 5: Schematic of an experimental apparatus for highly advanced liquid ammonia direct injection testing (Zacharakis-Jutz 2013). 14 No 16 ENERGY H IG HLIG HTS
conventional to slightly early diesel injection tim- do not avoid CO2 emissions completely but rath- ings. However, it was observed that conventional er reduce them substantially. injection timing or even earlier injection timing was insufficient to achieve more than 40% am- SPARK-IGNITION ENGINES (SIE) monia content in fuel. Thus, in an attempt to The use of ammonia as sole fuel for SE-engines increase the operating range and maximum per- is possible but requires significant changes to the cent of ammonia in the fuel, highly advanced ignition hardware. For instance, ammonia as sole injection timing was used. Such highly advanced fuel has been patented by Toyota where they injection timing transforms conventional diesel suggest that several plasma jet igniters arranged combustion into a homogeneous charge com- inside the combustion chamber or plural spark pression ignition (HCCI) combustion. The highly plugs that ignite the ammonia at several points advanced injection allows the heat loss due to will facilitate ammonia combustion (EP 2378105 the vaporization of the ammonia to be mitigated A; EP 2 378 094 A1). Those changes are not trivial over a longer time period thus reducing its nega- and would probably require the redesign of the tive effects (Zacharakis-Jutz 2013). entire cylinder head. As of now, there is no sin- gle fuel asset on the market which would be at The technical retrofitting efforts will have to the serial production level or even close to that. include additional fuel installations (tank, mix- More promising are double-fuel applications. Hy- ing tank, pumps, and valves), inject assembly drogen dissociates at 400 °C and can be used as a upgrade, engine management software (com- combustion promoter for ammonia as fuel. A hy- pression ignition timings) and extensive exhaust drogen content of 3-5% weight basis is the mini- treatment system. The implementation of CI en- mum amount of hydrogen required as combus- gine technology is feasible and requires moderate tion promoter (Starkman and Samuelsen 1967). retrofitting only. A significant drawback, how- For comparison: Using gasoline as a combustion ever, is the unstable performance at alternating promoter requires a compression ratio of 10:1 loads. The use of pilot fuels for NH3 engines is a for optimal operation with a gasoline content of double fuel technology. Therefore, these engines 30% (Grannell et al. 2008). C-RIO NH3 Fuel Controller Supercharged 2 Stage Surge Tank Surge Tank Data Acquisition System Ocilloscope Intake Air In Gas Analyzer Charge Pressure Amplifier Relief Valve Fuel line Heating Controller NH3 Injector Pressure Sensor Ammonia Gas Constant Temperature Spark Plug Exhaust Out Container Ammonia Ammonia Liquid Cooling Water Speed and Torque Signal 138.17 g Gasoline Electronic Balance Fuel 25.76 g Pump Encoder Dynamometer Electronic Balance CFR Engine Figure 6: Schematic of an experimental setup for testing gaseous ammonia direct injection (Zacharakis-Jutz 2013). ENERGY H IG HLIG HTS No 16 15
Figure 7: Ammonia storage facility in Japan (Harding 2020). Researchers from Iowa State University (USA) and comprehensive exhaust after-treatment sub- conducted a trial with a Cooperative Fuel re- systems. This automatically reduces the number search (CFR) Engine and had to overcome signifi- of possible applications. The large space demand cant upgrade challenges while adjusting the in- paired with a limited response time to fast chang- jection assembly for the gaseous ammonia usage. ing load demands indicates that two common applications are likely: In stationary power gen- Furthermore, they (Zacharakis-Jutz 2013) as- eration facilities and as naval propulsion systems. sessed that the required changes and add-ons Both applications could provide a significant con- for the ammonia injection such as an ammonia tribution towards global GHG emission reduction vaporizing unit, an ammonia gas preheating and if implemented at a large scale. ammonia direct injection system, are not suit- able for small-scale engines. With respect to While the usage of ammonia for power gen- retrofitting efforts, the statements made about eration may sound like fiction for the European CI engines apply as well: The subsystems to be audience, it does play an essential role in Asian modified are injection assembly, engine manage- (Japan, Korea, China) future energy strategies ment and exhaust after treatment. In the case (Figure 7) (Harding 2020). Japan for instance is of SI engines the injection assemblies are more strongly heading towards ammonia usage in the complex and voluminous. near future. Green ammonia is supposed to be generated by renewables (though imports are NH3 AS A FUEL OF THE FUTURE needed) and used in gas turbines for power gen- As of today, it is not easy to say how the future eration. Japanese industries conducted successful for ammonia as a fuel for combustion engines may tests and are now able to engage 100% ammonia look like. From an engineering perspective, the an- driven turbines (without any pilot fuels). Within swer is positive. All the challenges and setbacks the near future, ammonia will cover at least 1% described above are manageable issues and all of the country’s electricity demand. these issues can be solved with state-of-the-art technologies. All required technologies are avail- In general, NH3 represents a very economic stor- able and the only thing to do is to find applications age option for renewable power. It is also much where the advantages of ammonia combustion easier to handle than storing electric power in dominate over the existing disadvantages. secondary cells or hydrogen. Another promising application is in the maritime sector. The future Based on the research discussed above, it is obvious of naval propulsion systems is on the brink of un- that when using ammonia a volumetric enlarge- dergoing significant changes. Political and public ment of equipment is unavoidable: larger tanks demands result in national and international en- with additional equipment, the usage of pilot fuels vironmental regulations and expect the industry 16 No 16 ENERGY H IG HLIG HTS
to provide solutions. Ammonia is one of several dropower stations is possible if certain geological mature solutions to address these challenges and and topographic conditions are met, but public will compete with LNG, LPG, hydrogen, biofuels acceptance is low. Flywheel storage technology and synfuels. From many points of view ammo- is not yet widely established but appears prom- nia is a strong competitor and makes especially ising. Chemical energy storage in newly synthe- sense if being implemented with a strategic ap- sised compounds seems an interesting pathway. proach and not in a case-by-case scenario. Sev- eral research activities provided prove of concept According to the second law of thermodynamics, for ammonia technologies but did not go beyond each conversion is ultimately coupled with loss- laboratory and test environments yet. The next es in free energy (Atkins et al. 1990). Therefore, step could be the presentation of a fully function- the number of production steps for fuels should ing device as a minimum viable product being always be kept to a minimum. Hydrogen is the able to serve the market requirements. first fuel product of the electrolysis of water and shows the least loss of free energy (Holleman The project performed by Wärtsilä Corporation et al. 1985). Hydrogen can be used as a fuel in (a) with the support of the Norwegian Government fuel cells – as currently tested in pilot projects in (see chapter 5) might deliver such a device. The public transportation buses (Waterstofnet 2020) project successfully passed the laboratory trials and trains (VDI 2018), (b) blended into natural in Finland in 2020 and was then moved to Norway gas pipelines for heating purposes (Atlantic Coun- for further development. A maritime vessel with cil 2020; Sadler 2016) or (c) used as pure H2 as ammonia propulsion is expected to sail in 2023. If an chemical basic material (Gasunie Waterstof successful, that vessel would be much more than Services B.V. 2020). In The Netherlands, a consor- just a working prototype. It will be able to provide tium of the Gasunie pipeline operator, Groningen information on the necessary depth and the vol- harbour and Shell Netherland built a wind farm to ume of retrofitting naval engines for use of am- power electrolysers for H2 production. The pro- monia. Besides that, the vessel will allow both, to ject was started at the beginning of 2020 (N.V. formulate the ammonia supply infrastructure re- Nederlandse Gasunie 27.02.2020). In all those quirements and to evaluate the economic frame- technologies mentioned, the final product of the work conditions of using ammonia as fuel. incineration process is H2O. The disadvantages of using H2 are its highly inflammable and explo- Today, it is difficult to predict whether ammonia sive properties as well as its low energy density will win the competition for the fuel of the future as gas. Thus, before transport and storage, a liq- or will end up in scientific libraries as a “missed uefaction or pressurisation is necessary which is chance”. What is sure, however, is that if ammo- expensive and energy consuming (Table 1). nia propulsion will reach the market, it is going to be first in the maritime sector. Hydrogen can be further on processed to am- monia which is mostly known as a precursor for 7. CONCLUSIONS AND OUTLOOK nitrogen fertiliser production (nitrates and urea), but is also used as fuel since many decades. NH3 Electricity production from renewable sources may also serve as a chemical storage substance is well established. From 2018 on it became for H2. Catalytic dissociation of ammonia produc- cheaper on the international energy market than es N2 and H2. The hydrogen can then be used in all electricity produced by fossil power plants (Kost applications mentioned in the paragraph above. et al. 2018; The International Renewable Energy NH3 is easier and safer to handle and to transport Agency 2019). Decarbonising the economy de- than H2. Applications supplying power in remote mands both, energy storage options for time areas are already established (GENCELL WORLD- periods when renewable energy sources are not WILD 2020). Since additional transformation available and production of carbon neutral or no- steps cause further energy losses, direct uses of carbon fuels for mobility and e.g. heating. Large ammonia should be preferred. The most prom- scale storage of electricity in batteries is current- ising short term NH3 applications are in marine ly not economic. Physical storage in pumped hy- ENERGY H IG HLIG HTS No 16 17
vessels. Both, ammonia driven fuel cells (SHIPFC Fischer-Tropsch syntheses. On the source to tank 2020) and internal combustion engines (Wärtsilä basis, NH3 as a fuel is superior to H2 and metha- Helsinki Campus 2020) are on the brink of their nol. The efficiency of the NH3 fuel cells, however, first real life tests. Both technologies will provide has to be improved to sustain the cost advantage CO2- and SOx- emission free mobility. However, of NH3.(Zhao et al. 2019) such internal combustion engines need selective catalytic reduction (SCR) treatment systems) be- Ammonia is toxic but self-alarming to humans due cause the NH3, N2O and NOx emissions are high. to its pungent smell and it is neither inflammable These treatment systems are mature and well nor explosive. Ammonia is widely used as a cooling established technologies in ships, as they are al- agent in the food industry, in sporting arenas and ready used with carbon based fuels for reducing in emission treatment systems in ships. NH3 pro- NOx emissions (MAN Energy Solutions 2019). duction, transportation and distribution by ships These combined technologies would have a huge and trucks is common practise. Safety routines are positive impact on decreasing the pollution with well established during maintenance and repair SOx, PM and heavy metals in harbours and coast- works (Bundesministerium für Umwelt, Natur- al regions since the fuels currently used in most schutz und nukleare Sicherheit 2018; MAN Energy large ships are waste products from the crude Solutions 2019). The practical obstacles for large oil refining processes and are highly enriched in scale NH3 usage seem smaller than for H2 usage. substances hazardous to health. The concentra- tions permitted for these hazardous substances Ammonia is one of the most commonly produced in shipping fuels are currently much higher than commodities on a global scale. In 2014 approx. for land based mobility fuels (Umweltbundesamt 113 x 106 tonnes of NH3 were produced glob- - UBA) - but this may change soon. ally. Production, transportation and distribution capacities are available on all continents (Figure Zhao et.al. (2019) estimated the costs for differ- 8) (Ritchie and Roser 2020). Countries with large ent non-fossil fuels from source-to tank in cars. agricultural and industrial sectors show high lev- He compared several hydrogen-, nitrogen and els of production. carbon-based fuels produced from renewable electricity, H2 from electrolysis, methanol and Using NH3 as fuel would require a significant upscal- Figure 8: Global nitrogen fertilizer production in 2014. Global production in 2014 was 113.31 * 106 tonnes (Ritchie and Roser 2020). 18 No 16 ENERGY H IG HLIG HTS
Figure 9: Global map of photovoltaic power potential(THE WORLD BANK, 1818 H Street, NW Washington, DC 20433 USA 2020). ing of the production capacities. Under the given In the future we will surely experience intensified conditions this seems a manageable task and vari- research and development for using fuels on a ous CO2-free or low CO2- routes are thinkable. On a nitrogen basis. The prime advantages of nitrogen larger scale, additional plants for ammonia produc- based fuels are both, the intrinsic lack of carbon – tion would be needed. If powered with renewable with exception of urea - as well as the technolog- electricity for the electrolysis of water, the overall ical maturity of their production, transport and CO2 emission could be substantially reduced. Many storage. As the various propulsion engine and of the countries with a large NH3 production output combustion technologies reach technical matu- are located in the global Sunbelt (Figure 9) between rity, nitrogen based fuels will certainly become 35th degrees of northern and southern latitude, attractive fuels for a decarbonizing world. where global yearly irradiation is the highest. These regions are very well suited for solar electricity pro- For the next years it appears to be a prudent di- duction. The German plant manufacturer Thyssen- versification strategy for NATO nations and part- Krupp already offers small scale Ammonia pro- ners to establish a balanced strategy of invest- duction plants with H2 obtained by electrolysis of ments in Power to Liquid technologies at home water with electricity gained from renewable sourc- and in politically stable regions and to include es (thyssenkrupp Industrial Solutions AG 2020). nitrogen fuel research in their portfolio. This will Upscaling of these plants is surely possible. MAN ensure own technological competence and lead- Energy Solutions (Denmark), the producer of two- ership for promising technologies. stroke NH3 internal combustion engines for ships, proposes the production of NH3 fuel in plants in the ACKNOWLEDGMENTS Australian deserts, powered by electricity from so- The lead author thanks the NATO Energy Security lar parks (MAN Energy Solutions 2019). Centre of Excellence for a fellowship grant as well as the librarians of the University of Bayreuth and Hydrazine is highly toxic and applications for the Dr. Gintaras Labutis from the Lithuanian Military general public are unlikely. It is currently used as a academy for help in obtaining literature and sta- fuel in space travel and military applications only. tistical information. Thanks also go to Cpt Juozas Nitrate and urea based fuels are in early laboratory Latvys (LTU) for excellent support during the ed- testing phases. Whether these fuel-technologies iting process. will reach marketability is not yet conceivable. ENERGY H IG HLIG HTS No 16 19
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