GB2613021A

GB2613021A - Fluid processing system for renewable energy power supplies

Info

Publication number: GB2613021A
Application number: GB2116813.3A
Authority: GB
Inventors: Woods Andrew; Elliott Matthew; Douglas Robert
Original assignee: Catagen Ltd
Current assignee: Catagen Ltd
Priority date: 2021-11-22
Filing date: 2021-11-22
Publication date: 2023-05-24
Also published as: WO2023089184A1; GB202116813D0

Abstract

Fluid processing system 100A, such as a hydrogen production system or an e-fuel production system, is connected to renewable energy electrical power supply 5. Control system 150 controls the operation of apparatus 10 within the system depending on the available electrical power and/or on electrical power consumption values. Controlling the operation of the system may involve controlling the performance of chemical reactions performed by the system. The control system controls the operation of apparatus to adjust an electrical power consumption of the system and/or to adjust an electrical power consumption of processes, such as chemical reactions, performed by the system. The apparatus may include reactors 10 in which chemical reactions may take place. The system may control rate at which chemical reactions take place by controlling the flow rate, temperature, pressure, or level of reactant.

Description

Fluid Processing System for Renewable Energy Power Supplies

Field of the Invention

This invention relates to fluid processing systems. The invention relates particularly to systems for 5 use in the producflon of hydrogen or e-fuel.

Background to the Invention

Fluid processing systems may be configured for a variety purposes including the production of hydrogen or e-fuel. or for related processes such as CO2 sequestration or capture, fluid delivery 10 and/or fluid storage. It is desirable to power such systems using a renewable energy source, e.g. wind power, wave power or solar power. It is also desirable to locate such systems close to the renewable energy source since the renewable energy is transformed at site. However, the power supplied by renewable energy sources is variable which is problematic for equipment, e.g. electrolysis-based hydrogen production equipment, which requires a steady power supply.

It would be desirable to provide a fluid processing system that is suitable for use with renewable energy sources.

Summary of the Invention

From a flrst aspect the invention provides a fluid processing system as claimed in claim 1.

In preferred embodiments, at least one of said at least one fluid processing apparatus comprises a chemical reactor, said at least one process comprising at least one chemical reaction and said fluid comprising at least one chemical reactant for said at least one chemical reaction, wherein said reactor is configured to perform said at least one chemical reaction, and wherein said control system is configured to control the operation of said at least one fluid processing apparatus by causing said reactor to control the performance of said at least one chemical reaction, and wherein controlling the performance of said at least one chemical reaction optionally involves adjusting the rate of the respective reaction, or stopping the reaction, or starting the reaction. The control system may be configured to cause the reactor to control at least one characteristic of said at least one reactant.

Said at least one characteristic may comprise any one or more of a quantity of said at least one reactant in said reactor, a flow rate of said at least one reactant in said reactor, or a temperature of said at least one reactant in said reactor. The reactor typically includes at least one fluid reservoir for storing said at least one reactant, and wherein said reactor is configured to control the performance of said at least one chemical reaction by controlling a flow of one or more reactant from said at least one fluid reservoir. The reactor typically includes at least one fluid conduit configured to define a fluid flow path, and wherein said reactor is configured to control said at least one chemical reaction by controlling any one or more of a quantity of said at least one reactant in said fluid flow path, a flow rate of said at least one reactant in said fluid flow path, or a temperature of said at least one reactant in said fluid flow path. The reactor typically includes at least one reaction zone for performing said at least one chemical reaction, and wherein said reactor is configured to control said at least one chemical reaction by controlling any one or more of a quantity of said at least one reactant in said at least one reaction zone, a flow rate of said at least one reactant in said at least one reaction zone. or a temperature of said at least one reactant in said at least one reaction zone.

Typically, said at least one fluid processing apparatus comprises heating means for heating said fluid, and wherein said control system is configured to control the operation of said at least one fluid processing apparatus by causing the heating means to control a temperature of said fluid. Said at least one fluid processing apparatus typically includes at least one fluid reservoir; and wherein said control system is configured to control the operational said at least one fluid processing apparatus by causing the heating means to control a temperature of fluid in said at least one reservoir. The heating means may be included in said reactor and is operable to heat the fluid in said reactor.

Optionally, said at least one reservoir is included in said reactor and wherein said heating means is operable to heat fluid in said at least one reservoir, and wherein said at least one reservoir may comprise at least one reservoir for storing any one or more of: said at least one reactant; at least one reaction product; at least one reaction by-product; and/or at least one carrier fluid, any of which may be mixed or stored separately. One or more reservoir may be configured to supply fluid to said reactor, and/or wherein one or more reservoir is incorporated into a fluid flow path of the reactor; preferably serving as a fluid buffer.

Said heating means may comprise one or more heating apparatus, preferably an electrically powered heating apparatus, optionally an electric furnace such as an electric tube furnace.

Typically, said at least one fluid processing apparatus comprises fluid driving means for causing said fluid to flow in said at least one fluid processing apparatus, and wherein said control system is configured to control the operation of said at least one fluid processing apparatus by causing the fluid driving means to control a flow of said fluid in said at least one fluid processing apparatus, and wherein said fluid driving means optionally comprises one or more instance of any one or more of a blower, a fan or a pump, and is preferably electrically powered.

Typically; said reactor includes at least one fluid flow control device: optionally one or more valve and/or one or more fluid injector, configured to control the supply of said at least one reactant to said reactor, optionally to a fluid flow path and/or a reaction zone of the reactor, wherein said reactor is configured to control the performance of said at least one chemical reaction by controlling the operation of said at least one fluid flow control device.

Typically. said reactor includes at least one sensor or measurement device configured to measure 40 one or more characteristic of the fluid at one or more location in the reactor, wherein said one or more characteristic may comprise any one or more of the following fluid characteristics low rate, temperature, chemical composition, pressure, reactant level.

Optionally, the control system is configured to determine at least one power consumption value for 5 the or each process, preferably an actual or real-time power consumption value.

Advantageously, said control system is configured to control the operation of one or more of said at least one fluid processing apparatus in order to adjust an electrical power consumption of the or each fluid processing apparatus, and/or to adjust an electrical power consumption of at least one 10 process performed by the or each fluid processing apparatus.

Said at least one electrical power consumption value may comprise an allocated power consumption value, and the control system may be configured to determine a respective allocated power consumption value for said at least one fluid processing apparatus and/or for said at least one process for allocating the available electrical power amongst said at least one fluid processing apparatus and/or for allocating the available electrical power amongst said at least one process, and wherein, preferably, said control system is configured to control the operation of the respective fluid processing apparatus and/or the respective process to control the power consumption of the or each respective fluid processing apparatus and/or the respective process in accordance with the respective allocated power consumption value. Said at least one electrical power consumption value optionally includes any one or more of: a minimum power consumption value; an optimum power consumption value; a maximum power consumption value, and wherein said control system is configured to determine said respective allocated power consumption value depending on any one or more of a respective minimum power consumption value, a respective optimum power consumption value and/or a respective maximum power consumption value for the respective fluid processing apparatus or process, and/or depending on a respective tolerance value indicating a power adjustment tolerance of the respective fluid processing apparatus or process.

Optionally, said at least one electrical power consumption value comprises an actual or measured power consumption value for the, or each; fluid processing apparatus; and/or for the or each process of the or each fluid processing apparatus, and wherein said control system is configured to determine said respective allocated power consumption value depending on the actual or measured power consumption value for any one or more of said at least one fluid processing apparatus and/or said at least one process.

In some embodiments, depending on said available power; said control system is configured to stop the operation of any one or more of said at least one fluid processing apparatus and/or said at least one process, and/or to reduce the power allocated to any one or more of said at least one fluid processing apparatus and/or said at least one process in order to increase the available power.

In some embodiments, depending on said available power, said control system is configured to cause at least some of said available power to be stored as heat by heating fluid in said at least one fluid reservoir.

Preferably, said control system is configured to control the operation of said at least one fluid processing apparatus and/or of said at least one process using at least one computer-implemented model of said at least one fluid processing apparatus and/or of said at least one process.

In some embodiments, said chemical reactor is configured to implement a thermochemical cycle for 10 producing hydrogen, and wherein, preferably. said at least one chemical reaction comprises the chemical reactions of the sulphur-iodine cycle.

In some embodiments, said chemical reactor is configured to synthesis fuel from hydrogen, and wherein, preferably, said at least one chemical reaction comprises the reverse water gas-shift reaction, the Fischer-T Pee, and synthesis of fuel from a methyl precursor.

In preferred embodiments. the system is connected to a renewable energy electrical power supply system to receive electrical power therefrom.

In preferred embodiment, said at least one fluid processing apparatus comprises at least one conduit configured to provide at least one recirculating fluid circuit for performing said at least one process.

In preferred embodiments. said at least one fluid processing apparatus comprises at least one component configure to store a fluid mass, said at least one component optionally comprising one or 25 more instances of any one or more of: a heating device, a reservoir, a chamber, a conduit.

From another aspect the invention provides a method of controlling a fluid processing system as claimed in claim 25.

Preferably, said controlling involves controlling the operation of one or more of said at least one fluid processing apparatus in order to adjust an electrical power consumption of the or each fluid processing apparatus, and/or to adjust an electrical power consumption of at least one process performed by the or each fluid processing apparatus.

Preferably, said method includes determining a respective allocated power consumption value for said at least one fluid processing apparatus and/or for said at least one process for allocating the available electrical power amongst said at least one fluid processing apparatus and/or for allocating the available electrical power amongst said at least one process, and preferably controlling the operation of the respective fluid processing apparatus and/or the respective process to control the power consumption of the or each respective fluid processing apparatus and/or the respective process in accordance with the respective allocated power consumption value.

In preferred embodiments. the or each fluid processing apparatus includes one or more high thermal-inertia, electric tube furnace(s). Such devices can directly load follow and adjust H2 production (or e-fuel production or other fluid processing) based on the total excess power available at the wind farm or individual turbine or other renewable energy source. Preferably, the or each fluid processing apparatus includes one or more fluid reservoirs for containing a thermal fluid mass to provide thermal inertia to absorb (and store) as heat energy excess electrical power available at the wind farm or individual turbine. This reduces the need for other additional plant at site such as high-cost battery materials that are in high demand due to the electrification of vehicles.

Optionally, at least one of the fluid processing apparatus comprises a chemical reactor configured to implement a thermochemical cycle for producing hydrogen (FI2), in particular hydrogen (H2) gas, by splitting water into its hydrogen and oxygen components, i.e. to implement thermo-cyclic hydrogen production. Advantageously, the reactor is configured to implement the three reactions of the sulphur-iodine cycle (S-I cycle), preferably in a recirculating fluid reactor. In alternative embodiments, the reactor may be configured to implement any alternative thermochemical cycle for splitting water into hydrogen and oxygen.

Optionally, at least one of the fluid processing apparatus comprises a thermo-cyclic synthetic fuel, 20 especially e-fuel, production reactor. The, or each, thermo-cyclic e-fuel production reactor may be configured to synthesise fuel by means of the Reverse Water-Gas Shift (RWGS) reaction and the Fischer-Trospch (FT) processes, preferably in a recirculating fluid circuit.

In preferred embodiments, at least one of the fluid processing apparatus includes a recirculating fluid reactor that allows precise control of chemical composition, flow and temperature in one or more reaction zones where the reactants are converted to products by chemical reaction. Advantageously, mathematical model-based control is implemented at one or more control zones. Typically, operation of the reactor involves delivery of one or more gases and/or liquids into a closed system, or zone, of fixed known volume. Triangulation of multiple measurement sources, predictive models and calibrated gas/liquid delivery systems can ensure accuracy in a dynamic environment.

In preferred embodiments, the recirculating gas or liquid (fluid) production reactor comprises at least one, optionally two or more, recirculating gas systems or circuits with integral furnace(s), storage reservoir(s) and blower(s) or other fluid drive means. Heat may be regenerated through an integral heat exchanger(s). Advantageously, heat is stored in the fluid in the reactor, the fluid providing one or more thermal mass that provides thermal inertia in the reactor. Storing heat energy in the reactor in this way is advantageous in that it allows operation of the reactor to be tolerant of a fluctuating power supply such as a renewable power supply. For example, should the available electrical power decrease (or increase) with the result that less (or more) power is available to the reactor (e.g. to power the heating device(s) and/or other electrically powered components), then the thermal inertia in the reactor means that any resultant drop (or rise) in fluid temperature (e.g. in one or more of the

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reaction zones in particular) is delayed. Such a delay allows the reaction(s) being performed in the reactor to continue to be performed under the current operating conditions while also allowing time for the control system to make adjustment(s) to the operation of the reactor (e.g. to adjust flow rate and/or the quantity of one or more reactant) to compensate for the reduced (or increased) available power. Storing heat energy in the reactor may be facilitated by configuring the reactor such that it comprises one or more recirculating fluid circuit (which facilitates keeping fluid temperature in the circuit above ambient temperature and/or to be less affected by ambient temperature), and/or by using one or more components that are configured to contain a fluid thermal mass, e.g. thermal mass heating device(s), fluid reservoir(s), fluid chamber(s), fluid conduit(s) and so on.

Advantageously, the thermal inertia of components On particular furnaces and or fluid reservoirs) allows the reactor to be highly tolerant of a fluctuating energy supply (e.g. a renewable energy supply). Advantageously, systems embodying the invention are relatively small and are suited to integration with a renewable energy source, e.g. wind turbine(s). Embodiments of the invention may for example consume power in the range 50-500 kW. Preferred Embodiments of the invention are suitable for installation at a renewable energy site, e.g. a wind farm, for utilisation of available unused power at the renewable energy site, but may be scalable for larger capacity use. Use of electric furnace(s) (and/or other electrically powered heating apparatus) also facilitates integration with renewable energy supplies.

Further preferred features of the invention will be apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments and with reference to the accompanying drawings.

Brief Description of the Drawings

Embodiments of the invention are now described by way of example and with reference to the accompanying drawings in which: Figure 1 is a schematic diagram of a fluid processing system embodying one aspect of the invention, Figure 2 is a schematic diagram of an exemplary fluid processing apparatus, one or more instances of which may be included in the system of Figure 1; and Figure 3 is a schematic diagram of an embodiment of the fluid processing system configured for 35 hydrogen and e-fuel production.

Detailed Description of the Drawings

Referring now to Figure 1 of the drawings, there is shown, generally indicated as 100, a fluid processing system embodying one aspect of the invention. The apparatus 100 comprises a plurality 40 of fluid processing apparatus 10 and a control system 150. In Figure 1, four fluid processing apparatus 10 are shown by way of example only. More generally, the apparatus 100 may comprise one or more fluid processing apparatus 10. In embodiments where there is more than one fluid processing apparatus 10, each apparatus 10 may be of the same type or of a different type depending on the application. For example, as is described in more detail hereinafter, each apparatus 10 may be configured to perform H2 production and/or e-fuel production and/or associated processes such as CO2 sequestration, fluid storage or fluid delivery. Typically, the apparatus 10 operate independently of each other, but in some embodiments two or more apparatus 10 may operate in conjunction with each other.

The apparatus 100 is powered in use by a renewable energy power supply system 5. The renewable energy electrical power supply system 5 may take any convenient conventional form, and may generate electrical power (typically AC electrical power) from any renewable energy source, e.g. wind energy, solar energy. wave energy, tidal energy or geothermal heat energy. To this end, the power supply system 5 typically includes at least one turbine (e.g. wind, wave or tidal turbine -not shown), at least one electrical generator (not shown) driven by the at least one turbine, and at least one electrical power conversion system (not shown) for providing electrical power output, or at least one photovoltaic device (e.g. solar panel(s) -rot shown) and at least one electrical power conversion system (not shown) for providing electrical power output 6. The configuration of the renewable energy electrical power system 5 may be conventional and is not described further herein.

The electrical power generated by the power supply system 5 is variable depending on the availability of the relevant renewable energy source, e.g. on wind speed or sunlight intensity. Furthermore, the power supply system 5 may also be required to supply electrical power to an electrical grid 7, and the amount of power supplied to the grid may be variable depending on grid demand. Accordingly, the electrical power available to the apparatus 100 is variable.

Advantageously, the control system 150 is configured to control the operation of one or more of the apparatus 10 depending on the electrical power that is available to power the apparatus 100. The control system 150 is typically implemented by one or more suitably programmed or configured hardware, firmware and/or software controllers, e.g. comprising one or more suitably programmed or configured microprocessor, microcontroller or other processor, for example an IC processor such as an ASIC, DSP or FPGA (not illustrated).

Figure 1 shows a schematic diagram of an exemplary fluid processing apparatus 10. The apparatus 10 is electrically powered and, in use, is connected to the renewable energy electrical power supply system 5 in order to receive electrical power from the power supply system 5. The fluid processing apparatus 10 comprises fluid processing components that are electrically powered. In typical embodiments: the electrically powered components (not shown in Figure 1) include one or more instance of any one or more of the following components: fluid heater(s); fluid cooler(s); fluid driver(s); fluid valve(s); fluid injector(s); fluid compressor(s); fluid sensor(s). The specific composition and configuration of the apparatus 10 varies from embodiment to embodiment depending on what fluid processing the apparatus 10 is intended to perform, e.g. H2 production, e-fuel production or CO2 sequestration The composition of the fluid in the apparatus 10 also depends on the purpose of the apparatus 10.

Each apparatus 10 is configured to perform one or more process (shown as Process 1 to Process N in Figure 1, where N is greater than or equal to 1) on one or more relevant fluids. Each process may be performed independently of any other process, or in series with one or more other process and/or in parallel with one or more other process depending on the requirements of the embodiment, and the respective apparatus 10 is configured accordingly. By way of example, each process may involve any one or more of the following: fluid heating; fluid cooling; fluid driving; fluid flow control; fluid injection; fluid compression; fluid measurement; fluid storage. Alternatively or in addition, one or more of the processes may comprise performing one or more chemical reaction. Each apparatus 10 comprises one or more electrically powered component for performing the, or each. process Each process therefore has an electrical power consumption requirement (which can vary from process to process). Each process may be associated with a minimum power consumption value which indicates the minimum power required to perform the process. Each process may be associated with a maximum power consumption value which indicates the maximum power that can be used to perform the process. Each process may be associated with an optimum, or ideal, electrical power consumption value indicating a power consumption level that enables the process to be performed optimally. Each process may be associated with a tolerance value indicating an amount by which the power consumption of the process can be adjusted. Each of these values may be fixed (and may therefore be determined or calculated prior to use), or may be variable (and may therefore be determined or calculated during use). For example, any one or more of the values may vary during operation of the apparatus 10 depending on the operating conditions that arise. In any event, each value may be determined or calculated in any convenient manner, for example analytically (e.g. using a computer-implemented mathematical model of the apparatus), empirically and/or by measuring one or more characteristics of the operation of the apparatus and/or process during use. Each process may also be associated with an actual power consumption value which indicates the real-time measured power consumption of the process. Correspondingly, each apparatus 10 has an overall electrical power requirement (comprising the combined power requirements of its processes) and may be associated with any one or more of a minimum power consumption value, a maximum power consumption value, an optimum or ideal power consumption value, a tolerance value and/or an actual power consumption value. It will be understood that each apparatus 10 may include non-electrically powered components such as fluid conduit(s), fluid reservoir(s) and/or fluid chamber(s) as may be required to implement the respective processes.

Typically, each apparatus 10 includes a control system 14 configured to control and/or monitor the operation of the apparatus 10.

In some embodiments, the fluid processing apparatus 10 comprises a reactor 12 configured to 40 implement one or more chemical reactions in use, and which may therefore be described as a chemical reactor. Figure 2 shows a schematic diagram of an exemplary fluid processing apparatus comprising a chemical reactor 12. The apparatus 10 illustrated in Figure 2 is, by way of example only, configured to produce synthetic fuel, in particular e-fuel. It will be understood that the composition and configuration of the apparatus 10 is not limited to the specific composition and configuration shown in Figure 2. The reactor 12 typically includes one or more fluid conduit 16 defining a fluid flow path through or around the reactor 12. In preferred embodiments, the fluid conduit(s) form one or more fluid circuits 16 by which fluid (gas and/or liquid) may be conducted through or around the reactor 12. In preferred embodiments, the fluid conduit(s) 16 are arranged to define one or more fluid circuits by which fluid (gas and/or liquid) may be recirculated within the reactor 12 and, as such, the reactor 12 may be described as a recirculating fluid reactor. Typically.

the reactor 12 includes one or more furnace (or other heating device), one or more fluid storage reservoir and one or more blower (or other fluid driving device, e.g. fan or pump), all of which may be connected or coupled to the fluid circuit(s) as required. Heat within the reactor 12 may be regenerated by one or more heat exchanger and may be stored throughout the reactor, e.g. in the reservoir(s).

The, or each, fluid circuit 16 may be of any convenient construction, typically including any one or more of: pipe(s), tube(s), hosing, duct(s) and/or other fluid conduits. These may be formed from any convenient material, e.g. metal or plastics, and may optionally be thermally insulated and/or protected with one or more corrosion resistant coating. The fluid in the reactor 12 typically comprises any one or more of the following: reactant(s) for the relevant reaction(s) being performed by the reactor 12; reaction product(s) of the reaction(s); a carrier fluid (typically comprising nitrogen and/or other suitable gas(s) (in particular inert gas(es), or water), each of which may be gaseous or liquid as applicable. It will be understood that the carrier fluid may or may not be required depending on the embodiment.

Typically, the reactor 12 includes at least one reaction zone 18 for implementing the, or each reaction that the reactor 12 is configured to perform. The, or each, reaction zone 18 may take any suitable form, for example comprising a chamber or vessel incorporated into or connected to the fluid flow path or circuit, or being a part of a fluid conduit 16 that forms the fluid flow path. In any event, each reaction zone 18 is in fluid communication with the fluid flow path such that fluid may be delivered to and from the reaction zone 18 during use.

The reactor 12 typically includes, or is connected to, one or more fluid reservoirs 24 for storing quantities of gas and/or liquid, and which may also store energy (i.e. by storing fluid at a temperature that is elevated compared to the fluid in the circuit, and/or with respect to ambient conditions). Active heating of the reservoir(s), using any convenient heating means, e.g. a respective heating device for the, or each reservoir, may optionally be implemented to utilize excess available electrical power from the power supply system 5 when available. Such heating leverages the relatively high thermal inertia of the stored fluid(s) to reduce the heating requirement of the reactor during subsequent periods of relatively lower energy availability. The thermal inertia of the stored reactants allows the reactor 12 to operate effectively under variable or fluctuating energy supply.

A respective reservoir 24 may be provided for storing any one or more of the following fluids as required: reactant(s) for the relevant reaction(s) being performed by the reactor 12; reaction product(s) of the reaction(s); a carrier fluid. It will be understood that depending on the configuration of the reactor 12, one or more reservoir 24 may store a mixture comprising any one or more of: reactant(s); reaction product(s); carrier fluid. One or more respective fluid control device 15, e.g. a valve or a fluid injector. may be provided for controlling the flow of fluid into and/or out of each reservoir 24. One or more reservoir 24 (e.g. the system reservoir in Figure 2) may be incorporated into the fluid flow path and may act as a fluid buffer for use in controlling the operation of the 10 apparatus 10.

The reactor 12 typically includes fluid driving means 20 for causing the fluid to flow in or around the fluid flow path or circuit 16 as applicable. The fluid driving means 20 may any conventional form, e.g. one or more fans or blowers (for example including axial fans, propeller fans, centrifugal (radial) fans, mixed flow fans and cross flow fans), pumps (e.g. centrifugal pumps or positive displacement pumps), compressors and/or turbines, any or all of which are typically electrically powered. The fluid driving means 20 are preferably controllable to control the flow, and in particular the flow rate, of fluid in or around the fluid conduit(s) 16. The fluid driving means 20 may be connected to or incorporated into the fluid flow path at any suitable location(s). Flow of fluid in or around the fluid flow path may also be controllable using one or more valves 15 at one or more locations in the fluid circuit as required.

The reactor 12 typically includes heating means 22 for controlling the temperature of fluid in reactor 12, particularly in the reaction zones 18 and/or in the reservoir(s) 24. In typical embodiments, the heating means comprises one or more furnace, but may alternatively comprise any other suitable heating apparatus or device, e.g. a boiler. The heating means preferably comprises a containment or pressure flow conduit for a thermal mass for storage and transfer of heat. The heating apparatus may include any conventional heating device(s). The heating means 22 preferably comprises one or more electrically powered heating device, e.g. an electrical furnace (e.g. an infra red furnace, electrical tube furnace or flat bed furnace) or any other convenient heating device including electrical heater(s), infra-red heater(s), heat lamp(s), heat pump(s), heat exchanger(s) and so on. Use of electrically powered furnaces and/or other electrically powered heating devices is preferred as it facilitates integration with the renewable energy supply 5. Advantageously, the thermal inertia of the thermal fluid mass contained by at least some of the reactor components (e.g. furnaces, reservoirs, conduits and/or chambers) allows the reactor 12 to be highly tolerant of a fluctuating energy supply (e.g. a renewable energy supply). The heating means 22 are preferably controllable to control and/or modulate the temperature of the fluid in the respective part of the reactor 12, for example to control and/or modulate a base temperature in the respective reaction zone 18 and/or control the temperature of the reactants as required and/or to control the temperature of the fluid in the reservoir(s) 24. Each furnace or other heating apparatus may include any one or more of the following components: flow control and/or pressure regulating valve(s) with remote actuator(s) and/or mass flow controller(s) or other fluid injector(s); flow measurement device(s); pressure measurement device(s); temperature measurement device(s), fluid level and/or composition measurement device(s), each of which may be controlled by the control system 14 and/or provide information to the control system 14 as required.

The reactor 12 optionally includes one or more heat exchanger 26 to improve the efficiency of the reactor 12 in particular with respect to maintaining desired fluid temperatures in the reactor 12 energy efficiently. The heat exchangers 26 may be gas to gas type, gas to liquid type or liquid to liquid type as appropriate.

In preferred embodiments, the reactor 12 includes a plurality of control zones 28. Each control zone 28 is incorporated into the fluid flow path at a respective location. Any one or more of the control zones 28 may be equipped to measure at least one aspect of the reactor's operation. Each control zone 28 may be configured to measure one or more characteristic, or parameter, of the fluid at the respective location in the respective fluid circuit 16 into which it is incorporated. In particular, each control zone 28 may for example be configured to measure any one or more of the following fluid characteristics: flow rate, temperature, chemical composition, pressure, and may include any suitable conventional measurement device(s) for this purpose. Any one or more of the control zones 28 may be configured to control one or more characteristic of the fluid in the fluid conduit(s), e.g. the fluid flow rate, temperature, pressure and/or chemical composition, and/or to divert, direct or otherwise control the flow of the fluid, e.g. to a vent or to another component of the reactor 12. To this end, each control zone 28 may include one or more control devices 15, e.g. one or more valves, fluid injectors or fluid mixing devices, which are typically electrically powered. Any one or more of the respective control device(s) may be located at the respective control zone 28, in which case the control zone 28 controls the relevant fluid characteristic directly in its own locality. Alternatively, any one or more of the respective control device(s) may be located remotely from the respective control zone 28, in which case the control zone 28 controls the relevant fluid characteristic in one or more locations in the fluid circuit(s) remote from the control zone 28 itself. In such cases the control zone 28 may be said to include the control device in that it controls the operation of the control device.

In preferred embodiments, any one or more of the control zones 28 may be configured to monitor and control the introduction of one or more fluids (liquid(s) and/or gas(es) as applicable) into the fluid flow path (e.g. into the conduit(s) or other component included in or connected to the flow path), for example to control reactant levels and/or concentrations. To this end, each such control zone 28 may comprise one or more fluid flow control device 15, e.g. fluid injectors and/or valves. Each fluid injector may take any conventional form, typically comprising one or more valves and conduit(s) connected to one or more fluid sources, e.g. a canister, a compressor and/or one or more of the reservoirs 24, usually pressured fluid sources. Each fluid source may contain a single fluid or a mixture of two or more fluids, depending on the application and the tasks being performed by the respective control zone. Each fluid injector is operable to selectable inject one or more fluids into the respective fluid circuit(s) via one or more fluid inlets (not shown). Conveniently, the fluid inlet(s) are located at the respective control zone 28. although they may alternatively or additionally be located elsewhere in the fluid flow path. Optionally. one or more fluid injectors (not shown) may be provided for injecting fluid(s) into the reservoir(s).

In preferred embodiments, each reaction zone 18 includes or is associated with at least one respective control zone 28, the or each respective control zone 28 is operable (by control system 14 in preferred embodiments) to control one or more of the characteristics of the fluid in the respective reaction zone 18. Preferably, the or each respective control zone 28 is included in or located upstream of the respective reaction zone 18 (preferably immediately upstream of the respective reaction zone 18, e.g. at a fluid inlet of the respective reaction zone 18). Each control zone 28 is equipped with one or more sensor/measurement device 19 and/or one or more control device (e.g. valve and/or fluid injector) to allow it to monitor and/or control the relevant characteristic(s) of the fluid in the respective reaction zone 18 In order to communicate with other components of the apparatus 10, including for example remote analyser(s) and/or a control system, each control zone 28 may include a communications system including one or more wired and/or wireless communications devices as required.

The control zone 28 typically includes an enclosure in which at least some of its components are housed as is convenient. The enclosure may for example comprise a chamber incorporated into the fluid flow path, or a chamber to which the conduit(s) 16 is connected or passes through, or may comprise a part of one or more conduit(s) 16.

Optionally, the reactor 12 includes at least one separator 34 for separating the products produced by 25 the reactions implemented in the reaction zones 18. Each separator 34 may take any conventional form to suit the method by which the relevant products can be separated, e.g. condensation, distillation or liquid/liquid gravitic or gravitmetric separation.

The apparatus 10 includes a control system 14 for controlling and/or monitoring the operation of the system components, including, as applicable, the reaction zones 18, control zones 28, valves 15, fluid drivers 20, heaters 22, fluid injectors 15, separators 34 and any other controllable device (e.g. sensors 19 and so on). The control system 14 typically comprises a master controller which is typically implemented by one or more suitably programmed or configured hardware, firmware and/or software controllers, e.g. comprising one or more suitably programmed or configured microprocessor, microcontroller or other processor, for example an IC processor such as an ASIC, DSP or FPGA (not illustrated).

In preferred embodiments the control system 14 communicates control information to other components of the apparatus 10. for example the control zones 28, valves 15, fluid drivers 20 and/or 40 furnaces 22 in order to implement the reaction(s) being performed by the reactor 12. Process settings may be received via a process settings interface unit 51. The process settings may specify environmental conditions, for example in relation to temperature(s), flow rate(s), and/or pressure(s): and/or reactant levels (and/or concentrations) for the reaction zones 18. The control system 14 may also receive feedback information from other components of the apparatus 10, for example the control zones 28, sensors 19, measurement devices 19, valves 15, fluid drivers 20 and/or furnaces 22, in response to which the control system 14 may issue control information to one or more relevant system components. To this end the control system 14 may perform analysis of the measurements or other information provided by the control zones 28. This analysis may be carried out automatically in real time by the control system 14. Alternatively, or in addition, analysis of the system measurements and performance may be made by an operator in real time or offline. The operator may make adjustments to the operation of the apparatus 10 by providing control instructions via interface unit 51.

A safety controller (not shown) may be provided: which may receive alarm signals from one or more alarm sensors (not shown), e.g. gas sensors or leak detectors or emergency stops that may be 15 included in the apparatus 10, and provide alarm information to the master controller based on the alarm signals received from the alarm sensors.

In preferred embodiments, the control system 14, and more particularly the master controller is configured to implement system modelling logic: e.g. by supporting mathematical modelling software or firmware: for enabling the control system 14 to mathematically model the behaviour of the apparatus 10, and in particular of the reactor 12, depending on the process settings and/or on feedback signals received from one or more system components during operation of the apparatus 10.

Optionally, the control system 14 is configured to implement Model Predictive Control (MPG). Using MPC, the control system 14 causes the control action of the control zones 28 to be adjusted before a corresponding deviation from a relevant process set point actually occurs. This predictive ability, when combined with traditional feedback operation, enables the control system 14 to make adjustments that are smoother and closer to the optimal control action values than would otherwise be obtained. A control model for the apparatus 10 can be written in Matlab: Simulink, or Labview by way of example and executed by the master controller. Advantageously, MPG can handle MIMO (Multiple Inputs, Multiple Outputs) systems.

The control system 14 may include an artificial intelligence (Al) based model controller configured to 35 optimize operation of the apparatus 10 in real time in order to making best use of available energy, reactant levels and so on.

In some embodiments, the system comprises one or more reactor 12 configured to implement a thermochemical cycle (or thermo-cyclic reaction) for producing hydrogen (H2): in particular hydrogen 40 (H2) gas, by splitting water into its hydrogen and oxygen components, i.e. to implement thermo-cyclic hydrogen production. Thermochemical cycles combine heat source(s) with chemical reactions to split water into its hydrogen and oxygen components. Using a thermochemical cycle for producing hydrogen (H2), in particular hydrogen (H2) gas, may be referred to as thermo-cyclic hydrogen production. The sulphur-iodine cycle (S-Icycle) is an example of a thermochemical cycle for producing hydrogen. Advantageously, the reactor 12 is configured to implement the three reactions of the sulphur-iodine cycle (S-Icycle), preferably in a recirculating fluid circuit. In alternative embodiments, the reactor may be configured to implement any alternative thermochemical cycle for splitting water into hydrogen and oxygen.

The reactor 12 may be configured to implement a multi-stage thermochemical reaction cycle. The reactor preferably includes a recirculating fluid circuit to allow fluid, in particular gas, to be recirculated in the reactor to provide efficient use of heat and reactants. The production process is therefore low-energy and cost-efficient, producing green hydrogen gas (and oxygen as a by-product) from water and renewable electricity. Advantageously, the recirculating reactor includes a control system that creates control zones to facilitate each individual thermochemical reaction. Thermal and chemical degradation of materials at high temperatures (up to 1090°C) can readily be managed.

Producing hydrogen close to renewable energy sources such as a windfarm is highly desirable as the energy is transformed at site.

In some embodiments, the system comprises one or more reactor 12 configured to produce synthetic fuel, in particular e-fuel. Electrofuels, or e-fuels, are synthetic fuels produced using renewable electrical energy. E-fuels are liquid or gaseous hydrocarbon fuels and may be produced from synthetic hydrogen (H2) and carbon dioxide (CO2) sequestered from the environment. Typically, the hydrogen is produced by using energy from renewable sources such as wind, wave or solar power, to break water down into its component parts: e.g. by electrolysis or a thermochemical cycle such as the sulphur-iodine cycle. Examples of e-fuels include e-hydrogen, e-methane, e-methanol, e-kerosene, e-petrol and e-diesel. E-fuels can be burned carbon-neutrally since no extra CO2 is produced. In such embodiments, the reactor 12 may be configured to synthesise fuel, in particular e-fuel, by means of the Reverse Water-Gas Shift (RWGS) reaction and the Fischer-Trospch (FT) processes, preferably in a re-circulating fluid circuit. Advantageously, using a recirculating fluid circuit helps counteract any conversion inefficiencies in the RWGS reaction, where unconverted CO2 is not expelled, rather recirculated for conversion in the RWGS reaction zone during the 2nd, 3rd or NITh pass. Advantageously the reactor may operate at high temperature (>700°C) which facilitates a high RWGS reaction rate and improved yield of RWGS products compared to lower temperature operation. Advantageously, the system supports a high degree of flow control, in particular the flow of carbon dioxide and hydrogen through catalysts at a high rate, minimising the power requirements of the overall process. The preferred reactor 12 is therefore configured to implement the RWGS reaction and the FT process with the key reactants of CO2 and H2 being recirculated, thereby reducing waste products and increasing process efficiency. In preferred embodiments, hydrogen and carbon dioxide are fed into the reactor 12 which is configured to form a synthesis gas (CO and H2) that is then synthesized to produce a fuel precursor, which is synthesized to produce an e-fuel, for example, e-diesel or e-kerosene.

Preferably, the CO2 is sequestered directly from the atmosphere, ensuring an even lower carbon, ideally zero carbon, solution for e-fuel production. Any method or apparatus for sequestering CO2 from the atmosphere, or from elsewhere in the environment may be used. In some embodiments, at least one of the fluid processing apparatus 10 comprises an apparatus configured to sequester CO2 from the atmosphere. The apparatus may be configured to sequester CO2 from the atmosphere by any convenient means, for example CO2 scrubbing means. Alternatively, any conventional means for capturing CO2 may be provided. or CO2 may be received from an external supply, e.g. tank or reservoir.

In some embodiments, at least one of the fluid processing apparatus 10 comprises an apparatus for storing and/or delivering compressed gas, especially hydrogen.

Preferred embodiments of the invention include H2 production apparatus and/or e-fuel production apparatus that are suitable for installation at renewable energy sites, e.g. wind farms. Producing H2 and e-fuels close to renewable energy sources is highly desirable as the energy can be used to produce H2, and/or H2 can be transformed into e-fuel on site, which overcomes the problems associated with transporting gaseous H2. Liquid e-Fuel is significantly more easily transported due to its high mass density and high specific energy density. For example, a fixed volume of e-fuel typically has 7-8 times the energy content of the equivalent volume of hydrogen at a pressure of 350 bar.

By way of example, Figure 3 shows an embodiment of the fluid processing system, generally indicated as 100A, which includes fluid processing apparatus in the form of reactors 12A. 12B configured for hydrogen production by means of the S-I cycle. and in the form of reactors 12C, 12D configured for e-fuel production by means of Reverse Water-Gas Shift (RWGS) reaction and the Fischer-Trospch (FT) processes. Conveniently, the apparatus 100A may be configured such that hydrogen produced by the reactors 12A, 12B is supplied to the reactors 12C, 12D for use in e-fuel production.

The reactors 12A, 12B are configured to implement the three chemical reactions (i.e. processes) of the S-I cycle namely the Bunsen reaction (12 + SO2 + 2F-120 + 2HI + 1-12804), the decomposition of sulphuric acid (2H2SO4 + heat-. 2S0, + 21-120 + 02) and the thermal decomposition of hydrogen iodide (2H1 + heat.--* 12 + 1-12). Advantageously, the reactors 12A, 12B are configured such that the sulphuric acid produced by the Bunsen reaction is provided as a reactant for the decomposition of sulphuric acid process, the sulphur dioxide produced by the decomposition of sulphuric acid process is provided to the Bunsen reactor as a reactant for the Bunsen reaction, and the iodine produced by the decomposition of hydrogen iodide process is provided to the Bunsen reactor as a reactant for the Bunsen reaction. This may be achieved by any suitable configuration of the reactors 12A, 12B. For example a respective reaction zone 18 may be provided for each of the three reactions and fluid conduits 16 may be configured to direct the reactants and reaction products between the reaction zones 18 as required. One or more heaters (not shown in Figure 3) may be provided and controlled to heat the reactants as required. One or more blowers or ether fluid drivers (not shown in Figure 3) may be provided to drive the reactants and reaction products between the reaction zones via the conduits 16. One or more reservoirs ((not shown in Figure 3) may be provided for storing the reactants (separately or together as is convenient) and/or the reaction products (separately or together as is convenient). Optionally, the reactors 12A, 12B may include one or more pump, compressor, reservoir and/or output device for storing the produced hydrogen and/or for delivering it out of the apparatus 10.

The reactors 12A, 12B are configured to implement the following processes: the RWGS reaction (002 4. H2 liff-CO 4 H20), in Which carbon dioxide is reacted with hydrogen to produce carbon monoxide and water; the Fischer-rospch (FT} reaction CO 4. H2 CH2), in which a methyl precursor is synthesized from a mixture of carbon monoxide and hydrogen; and the synthesis of fuel from the methyl precursor (CH210-CxHy) It is noted that the precursor need not necessarily be CH2, for example it could be OHS or more generally CHa where the value of a may be 1,2! 3 or 4. In the example of Figure 3, the FT reaction and the synthesis of fuel from the methyl precursor are performed together, e.g. in the same reaction zone, but they may alternatively be performed separately, e.g. in respective reaction zones Advantageously, the reactors 12C 12D are configured such that the carbon monoxide produced by the RWGS reaction is provided for use in the FT reaction. This may be achieved by any suitable configuration of the reactors 120, 12D. For example a reaction zone 18 may be provided for the RWGS reaction and another reaction zone 18 for the FT reaction, and the fluid conduits 16 may be configured to direct the carbon monoxide from one reaction zone to the other. The fuel synthesis may be performed in the same reaction zone as the FT reaction or in a separate reaction zone, in which case the fluid conduits may be configured to direct the methyl precursor to the fuel synthesis reaction zone. Preferably, the reactors 120, 12D are configured to recycle, or recirculate. unused reactants and/or by-products of the fuel synthesis for use in the RWGS reaction. This may for example be achieved by configuring the fluid conduit(s) 16 to direct the unused reactants/by-products directly or indirectly (e.g. via a reservoir) from the reaction zone in which the FT reaction and fuel synthesis is performed (or from the separate reaction zone in which the fuel synthesis is performed as applicable) to the reaction zone for the RWGS reaction.

One or more heaters (not shown in Figure 3) may be provided and controlled to heat the reactants as required. One or more blowers or other fluid drivers (not shown in Figure 3) may be provided to drive the reactants and reaction products between the reaction zones via the conduits 16. One or more reservoirs ((not shown in Figure 3) may be provided for storing the reactants (separately or together as is convenient) and/or the reaction products (separately or together as is convenient).

Optionally, the reactors 12C. 12D may include means for sequestering carbon dioxide from air, and the reactor 120. 12D may be configured to directed the sequestered carbon dioxide to the reaction zone where the RWGS reaction takes place.

The control system 150 is configured to control the operation of the or each fluid processing apparatus 10 depending on the available electrical power and/or on one or more electrical power consumption value associated with each apparatus 10 (or reactor 12) and/or the, or each, process performed by the apparatus 10 (or reactor 12), e.g. the or each chemical reaction performed by the reactor 12. Advantageously, the control system 150 is configured to control the operation of any one or more of the fluid processing apparatus 10 in order to adjust the electrical power consumption of the respective apparatus 10, and/or the electrical power consumption any or more of the process(es) performed by the respective apparatus 10. Advantageously, the control system 150 is configured to allocate available electrical power amongst the fluid processing apparatus 10 (in embodiments where the system 100 has more than one apparatus 10) and/or to allocate available electrical power amongst the processes performed by the apparatus 10 (in embodiments where at least one apparatus 10 performs more than one process). The control system 150 may be configured to control the respective apparatus 10 and/or process depending on the electrical power allocated to the respective apparatus 10 or process. Power allocation may involve determining a respective allocated power consumption value for each apparatus 10 and/or process. The electrical power received from the supply systems may be distributed in the system 100 according to the allocated power consumption values.

The available electric power may comprise, or depend on, the electrical power that is available to the system 100 from the renewable electrical power supply system 5, and/or may depend on the power consumed by the or each other apparatus 10, and/or on the power consumed by the or each other process. The power that is available from the power supply 5 may vary depending on the availability of the relevant renewable energy source and/or on other load demands (e.g. from the grid) on the supply 5. The power consumed by each apparatus 10 or process may vary depending on a number of operational factors such as current operational settings, availability of reactants, overall power availability, whether or not an apparatus or process is off-line or broken, and so on. The actual power consumed by each apparatus 10 or process can be measured or otherwise determined, typically in real time, using information provided to the control system 150 (typically by the respective controller 14), which information may comprise information relating to the current operation of the or each process or reaction, e.g. any one or more of temperature, flow rate, reactant level(s), and which may be obtained using the relevant sensor(s) 19.

In typical embodiments, the control system 150 controls each apparatus 10 (or reactor 12) in cooperation with the respective control system 14 of the apparatus 10, typically by providing control information to the respective control system 14 to cause the control system 14 to control the respective apparatus 10 in the desired manner. The control system(s) 14 may be said to be part of the control system 150.

In preferred embodiments, the control system 150 is configured to control the operation of one or more of the chemical reaction(s) performed by one or more reactor 12. This may involve causing the reactor 12 to control at least one characteristic of one or more reactant, e.g. the quantity, flow rate and/or temperature of the reactant. Such characteristic(s) may be controlled in respect of any part(s) of the reactor 12, e.g. in one or more reaction zone 18, control zone 28, conduit 16 or reservoir 24 as applicable. Each chemical reaction may be controlled by controlling the quantity of the or each respective reactant the is supplied to the reactor 12. in particular to one or more reaction zone 18, control zone 28 and/or conduit 16 as applicable, from one or more reservoir that stores the respective reactant. Each chemical reaction may be controlled by controlling any one or more of a quantity of the reactant(s) in the fluid flow path and/or in one or more control zone 28, a flow rate of the reactant(s) in the fluid flow path and/or in one or more control zone 28, or a temperature of the reactant(s) in the fluid flow path and/or in one or more control zone 28.

The control system 150 may be configured to control the operation of each fluid processing apparatus 10 (and/or each process) by causing the heating means 22 to control the temperature of the fluid in the apparatus 10, or reactor 12, for example in any one or more of the reservoir(s), conduit(s), control zone(s) or reaction zone(s). Preferably, fluid temperature is controlled in one or more reservoir 24 for storing any one or more of: the reactant(s); at least one reaction product(s); at least one reaction by-product(s); and/or at least one carrier fluid, any of which may be mixed or stored separately, and wherein one or more reservoir may be configured to supply fluid (e.g. comprising one or more reactant) to the reactor, and/or wherein one or more reservoir may be incorporated into the fluid flow path of the reactor, preferably serving as a fluid buffer.

The control system 150 may be configured to control the operation of each fluid processing apparatus 10 (and/or each process) by causing the fluid driving means 20 to control a flow of said fluid in each apparatus 10. The control system 150 may be configured to control the operation of each fluid processing apparatus 10 (and/or each process) by controlling the operation of said at least one fluid flow control device 15, for example to control the supply of the reactant(s) to the reactor 12, optionally to the fluid flow path and/or the reaction zone(s) 18.

Advantageously, by controlling the or each reaction, or process, performed by the apparatus 10 or reactor 12, the electrical power consumed in performing the respective reaction or process can be adjusted. Controlling each reaction or process may involve adjusting the speed (or rate) of the reaction/process, starting the reaction/process. or stopping the reaction/process, any of which may be achieved using any of the means outlined above as applicable. For example, stopping or reducing the rate of the reaction or process reduces the power consumption associated with the reaction or process, whereas starting or increasing the rate of the reaction or process increases the power consumption associated with the reaction or process. Each reaction or process may be controlled such that it consumes its respective minimum power, or maximum power, or optimum or ideal power, typically depending on the relevant available or allocated power.

Depending on the available power, the control system 150 may be configured to allocate power to each process or reaction that corresponds to the respective optimum, or ideal, power consumption, or to a lower power consumption (e.g. the respective minimum power consumption), or to a higher power consumption (e.g. the respective maximum power consumption). Depending on the available power (e.g. if the available power falls below a threshold level), in particular the power available from the power supply 5, the control system 150 may be configured to shut down or stop the operation of any one or more of the apparatus 10, or any one or more of the processes performed by any one or more of the apparatus 10. Should the control system 150 determine that there is insufficient available power to operate any given process or reaction, it may terminate the process or reaction, or redistribute the available power such that the process or reaction may be performed at least at its minimum power level. Should the control system 150 save power by stopping one or more apparatus 10 or process, or by reducing the operating rate of one or more apparatus 10 or process, then it may be configured to distribute the saved power amongst the remaining operational apparatus 10 and/or process(es). As such, the saved power may add to the available power. To allow the control system 150 to determine how to allocate power amongst the apparatus 10 and or processes, each apparatus 10 and/or process may be assigned a priority level so that the control system can allocate power on a priority basis. The control system 150 may also determine how to allocate power depending on the respective tolerance value associated with the respective process.

Should the control system 150 determine that there is excess available power (e.g. more power than is required to operate each process at its optimum power level or its maximum power level) then the control system 150 may be configured to cause one or more of the apparatus 10 to store the excess power as heat energy by operating the heating means to heat the fluid in one or more reservoir 24 accordingly.

During use: the control system 150 may adjust the allocated power for any one or more of the apparatus 10 and/or any one or more of the process(es), depending on the available power, which may depend on the power available from the power supply system 5 and/or on the current or actual power being consumed by the respective apparatus 10 or process, and/or on the current or actual power being consumed by one or more other apparatus 10 or process, and/or on the allocated power for one or more other apparatus 10 or process.

In preferred embodiments, the control system 150 is configured to implement system modelling logic, e.g. by supporting mathematical modelling software or firmware, for enabling the control system 150 to mathematically model the behaviour of the apparatus 10 and/or the system 100, and in particular of each reactor 12. Optionally, the control system 150 is configured to implement Model Predictive Control (MPC). The control system 150 may include an artificial intelligence (Al) based model controller configured to optimize operation of the system 100 in real time in order to making best use of available energy: reactant levels and so on.

The following description outlines an exemplary control strategy for efficient distribution of power within in an embodiment where the system 100 has one apparatus 10 configured to perform a plurality of processes. A target for the control system 150 is to reach an equilibrium condition between processes within the reactor 12. For example, if the reactor 12 operates with three sequential processes, the equilibrium state would be such that the rate of production within each process was matched, and the level of reactants feeding each process was also balanced. The system 100 may become unbalanced due to system malfunction, operating characteristics changing, changing atmospheric conditions, highly variable power availability, operation close to the minimum load / generation condition, or other factors. Operation at or close to the equilibrium state is advantageous as this helps ensure maximum system uptime, however, flexibility to operate away from the equilibrium state allows for increased freedom for operation under a variable power supply.

1. Determine available power for reactor/apparatus operation -this may be obtained from the supply system 5 (e.g. from sensor data from the supply system 5), and/or from information provided by the apparatus 10.

2. Perform an evaluation of the readiness and capacity for each process within the apparatus 10, including any one or more of: a. Evaluation of process error states b. Evaluation of process feedstock / reactant levels (where relevant) c. Evaluation of storage capacity for system products d. Evaluation of process readiness states -is there a warm-up / setup energy required e. Evaluation of current operating condition 3. Optimise energy distribution across processes a. Perform an initial optimisation of the power distribution/allocation, which may be realised through regulation of the flow rate across each process as below: Process Power = Energy p0 X Flow Rate where the Energy Factor is used to characterise the respective power consumption requirement, and the flow rate is a value representative of the process rate. The energy factor may be a function of the flow rate, or other factors such as ambient conditions depending on the process. Each process may have a unique energy factor / energy factor function. The preliminary optimisation may be used to tend to bring the apparatus 10 closer to the equilibrium state. This can preferably be realised by an analytical approach where the reactant availability for each process is used to determine a priority as below (this may be an iterative calculation if the energy factor function is dependent on the flow rate): Storage Capcityp,",, A X Energy Factorp,"" A Ideal Powerp,,, = X Total Power Xi Storage Capcitv Process N X Energy Factorprocess Where Storage Capacity refers to the reservoir capacity less the current level within the reservoir for the process product.

b. Evaluation of the ideal power allocation/distribution to determine if this is compliant with system constraints and current operating regime including: * Minimum Power < Ideal Power < Maximum power for each process * Process is live and does not require warm-up * Process ramp rate is within constraints For cases where the ideal power for a given process is greater than maximum power, the excess power available may be distributed among the remaining processes. For cases where the Ideal Power for a given process is less than the Minimum Power, either the process may be stopped and its power reallocated, or the power allocation will be redistributed from the remaining processes to drive the given process at the minimum power level. This determination can either be made analytically, based on the process Storage Capacity relative to the other processes, or optionally guided further by power forecasting.

If one or more of the processes are not live (i.e. require a warmup prior to operation), the control system may either: allow the processes to ramp on, or redistribute the available energy to another process. The determination on whether to ramp the process on or not matches the Ideal Power < Minimum Power case outlined above. For cases where there is a substantial change in power delivery for a given process, it may be necessary to dampen or reduce the power requirement. Advantageously, the nature of the preferred reactors 12 are naturally tolerant to changes in power.

4. Send control signals to and process sensor data from the apparatus 10.

a. A control signal sent to production equipment is the flow / process rates for each process within the apparatus 10.

b. Sensor data is gathered for evaluation under point 2 during the subsequent time period.

c. Sensor data is also gathered to evaluate the energy factor in real time, to allow for performance correction, or system malfunction identification.

d. Sensor data gathered to schedule removal and distribution of final product(s).

5. Process repeats.

For embodiments in which the system 100 comprises more than one apparatus 10, each apparatus performing more than one process, the above control strategy may be modified as described below. In this case, the target for the control system 150 may be twofold: maximising energy utilisation across the multiple apparatus 10, and to reach an equilibrium condition between processes within each apparatus 10/reactor 12.

The following steps may be performed between steps 1 and 2 of the control strategy outlined above.

i. Perform an evaluation of the readiness and capacity for each apparatus 10, including any one or more of: a. Evaluation of apparatus error states b. Evaluation of storage capacity for apparatus products c. Evaluation of process readiness states -is there a warm-up / setup energy required d. Evaluation of current operating condition ii. Optimise energy distribution across the multiple apparatus: a. From the available power, determine the number of apparatus that can be operated.

b. For instances where instantaneous available energy is substantially below the total available energy, a power capacity overhead based on historic variance in power availability at the particular location / installation is added to the power availability for subsequent calculations. This may be for example 30% of total available generation capacity at the given site.

c. Available power is distributed across a suitable number of apparatus, based on the adjusted power availability above. The priority for selection of specific types of reactors, e.g. H2 production, E-Gasoline production etc. may be defined in part by the reliance of some apparatus on the products of others. Furthermore, there is capacity to adjust the priority on a case by case basis to suit a given production ratio for a given site.

d. Power is preferably distributed evenly across each apparatus (e.g. in terms of % of system max power), to allow for power variability.

It will be apparent from the foregoing that preferred embodiments relate to the arrangement and control of green hydrogen production systems operating under a variable power supply. A model-based control system is preferably used, which receives inputs from the variable energy source and/or the reactors, intelligently allocates energy to specific processes within the reactors to make best use of available energy. Optionally, the model-based control system utilizes Al to optimize the energy distribution within the system. The Al may be configured to account for the tolerance of each process to variable energy supply, allowing each individual process to work as efficiently as possible. Al may also be utilized to provide real-time forecast of upcoming energy availability based on historic trends.

Advantageously, the system 100 is located in close proximity to a renewable energy source, e.g. one or more turbines or PV panels, as for example may be found in a solar farm, wave farm. tidal farm, and so on. The hydrogen production system utilizes the renewable energy to produce green hydrogen, which can then be processed into compressed H2, or an alternative hydrogen carrier onsite such as: green synthetic e-fuel, liquid H2 and/or solid based carriers.

Renewable energy supplies typically provide variable power often in a quasi-unpredictable manner, and systems embodying the invention are advantageously tolerant of this variability. The individual components in the H2 production system should be tolerant to variable power, however this may not always be possible, and as such an intelligent control system is preferred. A model-based control system. optionally utilizing Al, can be configured to intelligently control the green hydrogen production systems and distribute the available renewable energy.

The control system 150 may receive input data from the renewable energy supply system 5 where possible to ascertain the available renewable energy. This facilitates the control system in completing the task of distributing energy effectively across the system 100. The control system 150 may also receive data from each apparatus 10 and/or each process, in order to evaluate whether or not each process is receiving sufficient power. Such evaluations may include evaluating actual temperatures (and/or other fluid characteristics or operating conditions) against respective set points, for example downstream of heating devices or elsewhere in the reactor. Also supplied to the control system may be information on reactant levels pertaining to each process throughout each apparatus 10. This information may used by the control system 150 to forecast reactant levels and schedule processes accordingly.

The control system 150 may receive data from the electrical distribution grid to understand the live and forecast potential for electrical export to the grid, or inversely the potential for energy use within 10 the system 100, optionally with the H2 production behaving as an energy storage medium -this process is frequently referred to as energy arbitrage.

The control system 150 may receive data from an external source and forecast demand for hydrogen-based fuels, including the requirements for specific types of H2 fuels e.g. e-gasoline. This 15 informs the control system of the priority for each apparatus 10 within the hydrogen production facility or other system 100.

The control system 150 may receive data from an external source on commercial aspects such as the current export price for electricity, or current commodity prices for hydrogen based fuels. The 20 control system 150 can use this data to modify the ratio of exported to utilized renewable energy in order to optimize the commercial output of the system 100.

The control system 150 may be provided with fixed inputs such as maximum grid export potential for the renewable energy installation (if the export potential is < generation potential), maximum storage 25 capacity for hydrogen products, expected extraction interval for stored hydrogen or hydrogen based fuel if applicable.

The control system 150 may be provided with operating characteristics for each process and/or apparatus 10 to allow these to be operated as effectively as possible. This may include minimum operating power levels, warm-up times, maintenance frequencies, and/or tolerance to variable power supplies which can be captured in a permissible process ramp rate. Optionally a sub-set of this data may be used as model / control system inputs.

The control system 150 may receive data as above and determine an ideal or optimum energy consumption rate for each process within each apparatus 10. This may be determined by one or more algorithms based on sensor data and/or or operating characteristics outlined above. These calculations can be performed in real time utilizing optional feedback to fine tune the process, with forward forecasting to prepare the system 100 for future operation. Optionally. artificial intelligence (Al) may be used to support the calculations. wherein the control system 150 can intelligently distribute power in the system 100. Alternatively or in addition analytical calculations, and/or conventional feedback control system operation may be employed.

The control system 150 may be configured to calculate when system maintenance should be performed, for example based on real time performance relative to expected behaviour. The control system 150 may be configured to calculate when reservoirs, or storage tanks, are expected to be filled, and forecast / schedule the distribution of green H2 or green H2 based synthetic fuels from the production site.

In preferred embodiments. output from the control system 150 comprises control signals indicating an optimised distribution of available renewable energy across the apparatus 10, optionally including 10 export to the grid. The control system 150 may output a desired or allocated power consumption for each process within each apparatus.

Optionally the control system 150 may communicate with the electrical grid system operator, to outline the potential for energy usage with a view to managing grid quality in a substantially 15 decentralised grid.

Optionally the control system 150 may communicate with third parties to broadcast the current and projected product levels, allowing effective extraction of hydrogen and hydrogen based fuels.

In some embodiments, data inputs for the control system 150 can be grouped into sub-categories: energy source, electrical grid requirements, commercial! market conditions, green H2 equipment parameters, green H2 storage. Optionally, a sub-set of these can be used depending on the installation. The energy source data input preferably provides information for current electricity generation, and where possible an indication of forecast future generation. The communication with the system operator! electrical grid may provide information on electricity demand and projected future demand. This is optional, in that the renewable energy supply may not be connected to the grid at all. or where there is not scope for such integration with a distributed generation grid. Optionally, the system operator may provide information around power quality and intelligently regulate the utilisation of renewable energy within the grid. Commercial information in terms of market pricing (for electricity, green hydrogen or green hydrogen based fuels) can optionally be provided to the control system. In addition to this, demand for a specific hydrogen or hydrogen based fuel production mix can be provided. Communication with the apparatus 10 advantageously provides information on green hydrogen and/or green hydrogen based fuel storage capacity. Communication with the apparatus 10 may provide the control system 150 with information on availability of equipment. characteristics of the apparatus 10 such as power consumption vs reactant usage and process products, tolerance to ramp up or down, cumulative operating hours and other relevant operating characteristics. Individual apparatus 10 may also provide data on available reactants where these are utilised (in thermocyclic reactors for example). Live performance parameters can also be provided to the control system 150 to indicate how processes are behaving, with safety indicators optionally being provided to allow the control system 150 to mitigate safety concerns or incidents.

In some embodiments, a function of the control system 150 is to effectively distribute the available renewable energy between export to the grid, and production of green hydrogen, or green hydrogen based fuels. The control system 150 may be configured in any convenient manner to perform this evaluation, e.g. analytical calculations, system modelling and/or Al modelling. In some embodiments, where the control system 150 manages export of generated electricity to the grid, the control system 150 is configured to calculate the potential or required export. The potential export may be determined by understanding the demand or capacity for export and the availability of renewable energy. Optionally, where there are contractual obligations for export. the control system may determine the required export to the grid. Once the export possibilities are understood, the control system 150 may evaluate an ideal green hydrogen or green hydrogen based fuel production mix. This may be determined from the current market demands for each particular product, including electrical export. This may be effectively considered as an unconstrained optimisation. Optionally, Al may be used to guide the optimisation rather than an analytical approach which may allow supplementary factors to be used in the evaluation. It may not always be possible to realise the ideal energy distribution; one or more apparatus 10 may be out of operation for scheduled maintenance for example. The control system may use real time data for each green hydrogen or green hydrogen based fuel process to optimise the energy distribution in light of the constraints on the installation. Optionally, where each production process comprises discrete sub-processes, the control system allocates energy across each of these sub-processes based on the apparatus characteristics, and where relevant sub-process reactant levels. Optionally, Al can be used to support this optimisation. Optionally, the control system 150 can evaluate cumulative operating hours and schedule maintenance. Optionally, the control system 150 can evaluate the current and projected production rates, along with the current storage levels and schedule distribution of the green hydrogen or green hydrogen based fuels produced. Optionally, in the absence of measured available energy data, the real time performance of each production process or sub-process is evaluated to act as an indicator of available energy.

In some embodiments, the system 100 is connected to a wind turbine with peak generating capacity 30 of approximately 500 kW, and for example comprises two each of thermocyclic H2 production reactors operating the SI cycle and E-Fuel generating reactors. In this preferred embodiment (and in some other embodiments) there is no export of renewable energy to the grid.

The invention is not limited to the embodiment(s) described herein but can be amended or modified 35 without departing from the scope of the present invention.

Claims

CLAIMS: 1. A fluid processing system connectable to an electrical power supply for supplying electrical power to the fluid processing system, the system comprising: at least one fluid processing apparatus 5 configured to perform at least one process on fluid in said at least one fluid processing apparatus; and a control system configured to determine an indication of available electrical power, and to determine at least one electrical power consumption value for said at least one fluid processing apparatus, wherein said control system is configured to control the operation of said at least one fluid processing apparatus depending on said indication of available electrical power and/or on said at 10 least one electrical power consumption value.
2. The system of claim 1. wherein at least one of said at least one fluid processing apparatus comprises a chemical reactor, said at least one process comprising at least one chemical reaction and said fluid comprising at least one chemical reactant for said at least one chemical reaction, wherein said reactor is configured to perform said at least one chemical reaction, and wherein said control system is configured to control the operation of said at least one fluid processing apparatus by causing said reactor to control the performance of said at least one chemical reaction, and wherein controlling the performance of said at least one chemical reaction optionally involves adjusting the rate of the respective reaction, or stopping the reaction, or starting the reaction, and wherein, optionally, said control system is configured to cause the reactor to control at least one characteristic of said at least one reactant, wherein said at least one characteristic optionally comprises any one or more of a quantity of said at least one reactant in said reactor, a flow rate of said at least one reactant in said reactor, or a temperature of said at least one reactant in said reactor.
3. The system of claim 2, wherein said reactor includes at least one fluid reservoir for storing said at least one reactant, and wherein said reactor is configured to control the performance of said at least one chemical reaction by controlling a flow of one or more reactant from said at least one fluid reservoir.
4. The system of claim 2 or 3, wherein said reactor includes at least one fluid conduit configured to define a fluid flow path, and wherein said reactor is configured to control said at least one chemical reaction by controlling any one or more of a quantity of said at least one reactant in said fluid flow path, a flow rate of said at least one reactant in said fluid flow path, or a temperature of said at least one reactant in said fluid flow path.
5. The system of any one of claims 2 to 4, wherein said reactor includes at least one reaction zone for performing said at least one chemical reaction, and wherein said reactor is configured to control said at least one chemical reaction by controlling any one or more of a quantity of said at least one reactant in said at least one reaction zone, a flow rate of said at least one reactant in said at least one reaction zone, or a temperature of said at least one reactant in said at least one reaction zone.
6. The system of any preceding claim, wherein said at least one fluid processing apparatus comprises heating means for heating said fluid, and wherein said control system is configured to control the operation of said at least one fluid processing apparatus by causing the heating means to control a temperature of said fluid, and wherein said at least one fluid processing apparatus optionally includes at least one fluid reservoir, and wherein said control system is configured to control the operation of said at least one fluid processing apparatus by causing the heating means to control a temperature of fluid in said at least one reservoir.
7. The system of claim 6, when dependent on any one of claims 2 to 5, wherein said heating means is included in said reactor and is operable to heat the fluid in said reactor.
8. The system of claim 7 when dependent on claim 6, wherein said at least one reservoir is included in said reactor and wherein said heating means is operable to heat fluid in said at least one reservoir, 15 and wherein said at least one reservoir may comprise at least one reservoir for storing any one or more of: said at least one reactant; at least one reaction product; at least one reaction by-product; and/or at least one carrier fluid, any of which may be mixed or stored separately, and wherein, optionally, one or more reservoir is configured to supply fluid to said reactor, and/or wherein one or more reservoir is incorporated into a fluid flow path of the reactor, preferably serving as a fluid buffer. 20
9. The system of any one of claims 6 to 8, wherein said heating means comprises one or more heating apparatus, preferably an electrically powered heating apparatus, optionally an electric furnace such as an electric tube furnace.
10. The system of any preceding claim, wherein said at least one fluid processing apparatus comprises fluid driving means for causing said fluid to flow in said at least one fluid processing apparatus, and wherein said control system is configured to control the operation of said at least one fluid processing apparatus by causing the fluid driving means to control a flow of said fluid in said at least one fluid processing apparatus, and wherein said fluid driving means optionally comprises one or more instance of any one or more of a blower, a fan or a pump, and is preferably electrically powered.
11. The system of claim 2 or any claim dependent on claim 2, wherein said reactor includes at least one fluid flow control device, optionally one or more valve and/or one or more fluid injector, configured to control the supply of said at least one reactant to said reactor, optionally to a fluid flow path and/or a reaction zone of the reactor, wherein said reactor is configured to control the performance of said at least one chemical reaction by controlling the operation of said at least one fluid flow control device.
12. The system of claim 2 or any claim when dependent on claim 2, wherein said reactor includes at least one sensor or measurement device configured to measure one or more characteristic of the fluid at one or more location in the reactor: wherein said one or more characteristic may comprise any one or more of the following fluid characteristics: flow rate, temperature; chemical composition, pressure, reactant level.
13. The system of any preceding claim, wherein the control system is configured to determine at least one power consumption value for the or each process, preferably an actual or real-time power consumption value.
14. The system of any preceding claim, wherein said control system is configured to control the 10 operation of one or more of said at least one fluid processing apparatus in order to adjust an electrical power consumption of the or each fluid processing apparatus, and/or to adjust an electrical power consumption of at least one process performed by the or each fluid processing apparatus.
15. The system of any preceding claim, wherein said at least one electrical power consumption value comprises an allocated power consumption value, the control system being configured to determine a respective allocated power consumption value for said at least one fluid processing apparatus and/or for said at least one process for allocating the available electrical power amongst said at least one fluid processing apparatus and/or for allocating the available electrical power amongst said at least one process, and wherein; preferably, said control system is configured to control the operation of the respective fluid processing apparatus and/or the respective process to control the power consumption of the or each respective fluid processing apparatus and/or the respective process in accordance with the respective allocated power consumption value.
16. The system of claim 15; wherein said at least one electrical power consumption value includes any one or more of: a minimum power consumption value; an optimum power consumption value; a maximum power consumption value, and wherein said control system is configured to determine said respective allocated power consumption value depending on any one or more of a respective minimum power consumption value, a respective optimum power consumption value and/or a respective maximum power consumption value for the respective fluid processing apparatus or process, and/or depending on a respective tolerance value indicating a power adjustment tolerance of the respective fluid processing apparatus or process.
17. The system of claim 15 or 16, wherein said at least one electrical power consumption value comprises an actual or measured power consumption value for the. or each, fluid processing apparatus, and/or for the or each process of the or each fluid processing apparatus. and wherein said control system is configured to determine said respective allocated power consumption value depending on the actual or measured power consumption value for any one or more of said at least one fluid processing apparatus and/or said at least one process.
18. The system of any preceding claim, wherein depending on said available power, said control system is configured to stop the operation of any one or more of said at least one fluid processing apparatus and/or said at least one process, and/or to reduce the power allocated to any one or more of said at least one fluid processing apparatus and/or said at least one process in order to increase the available power.
19. The system of any preceding claim, wherein said at least one fluid processing apparatus includes at least one fluid reservoir, and wherein, depending on said available power, said control system is configured to cause at least some of said available power to be stored as heat by heating fluid in said at least one fluid reservoir.
20. The system of any preceding claim, wherein said control system is configured to control the operation of said at least one fluid processing apparatus and/or of said at least one process using at least one computer-implemented model of said at least one fluid processing apparatus and/or of said at least one process.
21. The system of claim 2 or any claim dependant on claim 2, wherein said chemical reactor is configured to implement a thermochemical cycle for producing hydrogen. and wherein, preferably. said at least one chemical reaction comprises the chemical reactions of the sulphur-iodine cycle.
22. The system of claim 2 or any claim dependent on claim 2, wherein said chemical reactor is 20 configured to synthesis fuel from hydrogen and wherein, preferably said at least one chemical reaction comprises the reverse water gas shift reaction the Fischer-Trospch, and synthesis of fuel from a methyl precursor.
23. The system of any preceding claim connected to said electrical power supply system. wherein 25 said electrical power supply system is a renewable energy electrical power supply system.
24. The system of any preceding claim, wherein said at least one fluid processing apparatus comprises at least one conduit configured to provide at least one recirculating fluid circuit for performing said at least one process, and/or wherein said at least one fluid processing apparatus comprises at least one component configure to store a fluid mass, said at least one component optionally comprising one or more instances of any one or more of: a heating device, a reservoir, a chamber, a conduit.
25. A method of controlling a fluid processing system connectable to an electrical power supply for supplying electrical power to the fluid processing system, the system comprising at least one fluid processing apparatus configured to perform at least one process on fluid in said at least one fluid processing apparatus, the method comprising: determining an indication of available electrical power, and determining at least one electrical power consumption value for said at least one fluid processing apparatus; and controlling the operation of said at least one fluid processing apparatus depending on said indication of available electrical power and/or on said at least one electrical power consumption value.