Power-to-Gas Implementation for a Polygeneration System in Southwestern Ontario

Canada has stockpiles of waste petroleum coke, a high carbon waste product leftover from oil production with little positive market value. A polygeneration process is proposed which implements "power-to-gas" technology, through the use of electrolysis and surplus grid electricity, to use waste petroleum coke and biomass to create a carbon monoxide-rich stream after gasification, which is then converted into a portfolio of value-added products with the addition of hydrogen. A model implementing mixed-integer linear programming integrates power-to-gas technology and AspenPlus simulates the polygeneration process. The downstream production rates are selected using particle swarm optimization. When comparing 100% electrolysis vs. 100% steam reforming as a source of hydrogen production, electrolysis provides a larger net present value due to the carbon pricing introduced in Canada and the cost reduction from removal of the air separation unit by using the oxygen from the electrolysers. The optimal percent of hydrogen produced from electrolysis is about 82% with a hydrogen input of 7600 kg/h. The maximum net present value is $332 M when over 75% production rate is dimethyl ether or $203 M when the dimethyl ether is capped at 50% production. The polygeneration plant is an example of green technology used to environmentally process Canada's petroleum coke.