Building a Community-Integrated Low-carbon Hydrogen Supply Chain
Kanagawa Prefecture, City of Yokohama, Kawasaki City, Iwatani Corporation, Toshiba Corporation, and Toyota Motor Corporation
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Project name Ministry of the Environment: FY2015 Regional Cooperation and Low-carbon Hydrogen Technology Demonstration Project Introduction of fuel-cell forklifts in the Keihin Waterfront Area and demonstration of feasibility of building a low-carbon hydrogen utilization model
Planned project duration FY2015-FY2018 (4-year project)
Project Overview
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Trial of building a hydrogen supply chain, from the manufacture of CO2-free hydrogen produced using renewable energy to its storage, transport, and utilization; investigation of the commercial feasibility of the supply chain.
Realization of a simple integrated system for utilizing hydrogen, with the goal of contributing to future regional development and helping mitigate global warming.
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Project Overview
System flow of the entire project
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Project Overview
水素圧縮機 (50N㎥/h) Yokohama City Wind
Power Plant (Hama Wing) (1,980 kW)
Receiving/ transforming facility
(already built)
Water (H2O)
Renewable energy Hydrogen manufacturing Storage/compression
Keihin Waterfront Area
• Vegetable and fruit markets • Refrigerated warehouses • Distribution warehouses, etc.
Hydrogen (H2) 35 MPa
Transport Utilization
Supplying hydrogen using simple fueling trucks
(Optimum transport that addresses operational situations and needs)
To be newly installed inside the Hama Wing site
Fuel cell forklifts (Total 12 vehicles)
Low-pressure hydrogen storage
tank (800 N㎥)
Hydrogen fueling truck
(45 MPa: 270 N㎥)
Hydrogen storage and compression system
Water electrolysis system (10 N㎥/h)
Receiving/transforming/distribution panels, storage facility
Power storage system (150 kWh) Receiving/transforming/ distribution panels
Hydrogen manufacturing
system
Hydrogen compressor (50 N㎥/h)
TOSHIBA
Organizational Structure of the Project
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Ministry of the Environment Global Environment Bureau, Climate Change
Policy Division
Toyota Turbine and Systems Inc.
Toshiba Corp.
Manufacturing
Chairperson Prof. Emeritus Kenichiro Ota, Yokohama National University
Vice Chairperson Prof. Emeritus Yoji Uchiyama,
University of Tsukuba
Committee
Iwatani Corp.
Storage/transport
Japan Environment
Systems
Toyota Motor Corp.
Kanagawa Prefecture
Secretariat
Kawasaki City Toyota Industries Corp.
Yokohama City
Utilization
Wind Power Utilization
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Yokohama City Wind Power Plant (Hama Wing)
Receiving/ transforming facility
(already built)
Storage/compression
• Vegetable and fruit markets • Refrigerated warehouses • Distribution warehouses, etc.
Hydrogen (H2)
Transport Utilization
To be newly installed inside the Hama Wing site
Fuel cell forklifts
Hydrogen storage tank
Hydrogen fueling truck
Hydrogen storage and compression system
Hydrogen (H2)
Water electrolysis system
Receiving/transforming/distribution panels, storage facility
Power storage system
Hydrogen manufacturing
system
Hydrogen compressor
Partial utilization
TOSHIBA
Renewable energy
Water (H2O)
Hydrogen manufacturing
Receiving/transforming/ distribution panels
Keihin Waterfront Area
Utilization of CO2-free Electricity Generated at the Yokohama City Wind Power Plant (Hama Wing)
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Wind Power Utilization
Specifications
Manufacturer Vestas (Denmark)
Rated output 1,980 kW
Hub height 78 m
Blade diameter 80 m
Peak height 118 m
Hama Wing
Establishment of priority for the limited amount of wind-generated power, which fluctuates widely, and building a system that uses it optimally
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2015/1/6
0時 12時
2015/1/7 2015/1/8 2015/1/9
0時 12時 0時 12時 0時 12時
風力発電(10分値)
ハマウイング 風力発電10分平均値の推移データ
(2015年1/6~1/9)
Hama Wing wind power generation data (fluctuating)
Wind Power Utilization
Item Value Power generated
per year Approx. 2.20 million kWh
Facility operation rate 12.4 %
Trend in the 10-minute average of power generated by Hama Wing wind power plant (January 6–9, 2015)
Power generated by wind (over a 10-minute period)
noon noon noon noon midnight midnight midnight midnight
Hydrogen Manufacturing
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Yokohama City Wind Power Plant (Hama Wing)
Receiving/ transforming facility
(already built)
Renewable energy Storage/compression
Keihin Waterfront Area
• Vegetable and fruit markets • Refrigerated warehouses • Distribution warehouses, etc.
Hydrogen (H2)
Transport Utilization
To be newly installed inside the Hama Wing site
Fuel cell forklifts
Hydrogen storage tank
Hydrogen fueling truck
Hydrogen storage and compression system
Hydrogen (H2)
Water electrolysis system
Receiving/transforming/distribution panels, storage facility
Power storage system Receiving/transforming/ distribution panels
Hydrogen manufacturing
system
Hydrogen compressor
Partial utilization
TOSHIBA
Hydrogen manufacturing
Water (H2O)
Hydrogen Manufacturing
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• Electricity generated at Hama Wing will be used for electrolysis of water to manufacture hydrogen.
• Electricity generated at Hama Wing will also be used to power equipment, achieving CO2-free hydrogen manufacturing
e- e-
Cathode
Electrolyte
Anode
Power supply
H+
H H
O H H
O O H+
O H H
e- e-
Anode: 2H+ + 2e- → 2H2
Cathode: H2O → 1/2O2 + 2H++ 2e-
Hydrogen Manufacturing Hydrogen can be manufactured flexibly according to the fluctuating amount of wind-generated power
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Specifications (planned)
Size (m) D6×W2.5×H2.3
Type Solid polymer type
Manufacturing capacity 10 Nm3/h
Water electrolysis system (Toshiba Corp.)
Distribution board
Air tank
Ventilation fan
Air compressor
Chiller
Electrolyzer
Storage/Compression of Hydrogen
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Yokohama City Wind Power Plant (Hama Wing)
Receiving/ transforming facility
(already built)
Renewable energy
Keihin Waterfront Area
• Vegetable and fruit markets • Refrigerated warehouses • Distribution warehouses, etc.
Hydrogen (H2)
Transport Utilization
To be newly installed inside the Hama Wing site
Fuel cell forklifts
Hydrogen storage tank
Hydrogen fueling truck
Hydrogen storage and compression system
Hydrogen (H2)
Water electrolysis system
Receiving/transforming/distribution panels, storage facility
Power storage system Receiving/transforming/ distribution panels
Hydrogen manufacturing
system
Hydrogen compressor
Partial utilization
TOSHIBA
Storage/compression
Water (H2O)
Hydrogen manufacturing
Storage/Compression of Hydrogen • To ensure stable hydrogen supply, two days worth of hydrogen
will be stored. • When a hydrogen fueling truck comes to receive hydrogen,
hydrogen will be pressurized using a compressor and loaded into the truck.
Issue If no power is supplied from Hama Wing, the hydrogen compressor will not work and hydrogen cannot be delivered.
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Storing CO2-free Electrical Power
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Yokohama City Wind Power Plant (Hama Wing)
Receiving/ transforming facility
(already built)
Keihin Waterfront Area
• Vegetable and fruit markets • Refrigerated warehouses • Distribution warehouses, etc.
Hydrogen (H2)
Transport Utilization
To be newly installed inside the Hama Wing site
Fuel cell forklifts
Hydrogen storage tank
Hydrogen fueling truck
Hydrogen storage and compression system
Hydrogen (H2)
Water electrolysis system
Receiving/transforming/distribution panels, storage facility
Power storage system Receiving/transforming/ distribution panels
Hydrogen manufacturing
system
Hydrogen compressor
Partial utilization
TOSHIBA
Hydrogen manufacturing
Water (H2O)
Renewable energy Storage/compression
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Storing CO2-free Electrical Power A power storage system will be utilized to make it possible to supply power even when Hama Wing is not operational.
TOSHIBA
Hama Wing
Water electrolysis system
Hydrogen compressor
Power storage system
Wind turbine stopped
Hydrogen fueling truck
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Storing CO2-free Electrical Power Reusing end-of-life batteries from hybrid vehicles as secondary batteries makes sense environmentally.
Storage system (Toyota Turbine and Systems Inc.) 16
Specifications (planned)
Battery type Nickel metal hydride
No. of cells 180
Output 150kWh
Transporting Hydrogen
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Yokohama City Wind Power Plant (Hama Wing)
Receiving/ transforming facility
(already built)
Keihin Waterfront Area
• Vegetable and fruit markets • Refrigerated warehouses • Distribution warehouses, etc.
Hydrogen (H2)
Utilization
To be newly installed inside the Hama Wing site
Fuel cell forklifts
Hydrogen storage tank Low-pressure
Simple hydrogen fueling truck
Hydrogen storage and compression system
Hydrogen (H2)
Water electrolysis system
Receiving/transforming/distribution panels, storage facility
Power storage system Receiving/transforming/ distribution panels
Hydrogen manufacturing
system
Hydrogen compressor
Partial utilization
TOSHIBA
Transport
Water (H2O)
Renewable energy Hydrogen manufacturing Storage/compression
Transporting Hydrogen • Introduction of Japan’s first hydrogen fueling truck for
fuel-cell forklifts (1) Given the usage conditions of forklifts, compact fueling trucks are
essential. (Close proximity between usage locations and fueling locations, indoor usage, etc.)
(2) Hybrid trucks will be used to make the process more environment-friendly.
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Specifications (planned)
Vehicle used Hybrid Truck 4t Capacity 270 Nm3
Fueling equipment
Dimensions (m) D3.5×W1.8×H1.35
Tanks 2 (300 L, 45 MPa)
Hydrogen Utilization
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Yokohama City Wind Power Plant (Hama Wing)
Receiving/ transforming facility
(already built)
Renewable energy Hydrogen manufacturing Storage/compression
• Vegetable and fruit markets • Refrigerated warehouses • Distribution warehouses, etc.
Hydrogen (H2)
Transport 利用
To be newly installed inside the Hama Wing site
Fuel cell forklifts
Hydrogen storage tank
Low-pressure
Hydrogen fueling truck
Hydrogen storage and compression system
Hydrogen (H2)
Water electrolysis system
Receiving/transforming/distribution panels, storage facility
Power storage system
Hydrogen manufacturing
system
Hydrogen compressor
Partial utilization
TOSHIBA
Power storage Utilization
Keihin Waterfront Area
Water (H2O)
Receiving/transforming/ distribution panels
Hydrogen Utilization The fuel cell forklift unveiled in February emits zero CO2 during operation.
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Specifications (planned)
Maximum load 2,500 kg Refueling time 3 minutes
Hydrogen fuel capacity 13.4 Nm3
Duration of operation Approx. 8 hours*
*Similar to electric forklifts currently on the market
Fuel Cell Forklift (Toyota Industries Corp.)
Hydrogen Utilization The number of forklifts operated by Japanese companies is low to medium in most cases, and the way forklifts are used also varies widely. Therefore, validation will be carried out under a wide range of usage conditions.
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Introduction target Main demonstration objectives
Yokohama City
Central Wholesale Market, Main Branch (Vegetable and Fruit Section) Short distances, frequent use
Kirin Brewery Co., Ltd. (Yokohama Factory) Transport of heavy objects
Kawasaki City
Nakamura Logistics Inc. (Kawasaki FAZ Logistics Center) Use on multiple floors indoors, hydrogen fueling
Nichirei Logistics Group Inc. (Higashi-Ogishima Distribution Center) Use in the refrigerated transport industry
Introduction targets and main demonstration objectives
Transport/Utilization of Hydrogen Hydrogen usage by forklifts will be regularly tracked and user demand will be closely supported through daily optimized deliveries.
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Hydrogen manufacturing/supply location (Hama Wing)
Central Wholesale Market, Main Branch
Kirin Brewery Co., Ltd. Nakamura Logistics Inc. (Kawasaki FAZ Logistics Center)
Nichirei Logistics Group Inc.
Usage area (Kawasaki City) Usage area
(Yokohama City)
Usage area (Yokohama City)
Investigation of Future Project Feasibility (Current Cost)
Current Cost Evaluation
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Main factors behind high cost Facility cost
Maintenance cost Cost impact of small-scale demonstration (using only 12 forklifts)
Operation cost The High Pressure Gas Safety Act requires the constant presence of qualified persons (three) during hydrogen compression.
Electricity cost, fuel cost
Includes the cost of renewably generated power needed for water electrolysis and compression.
Other Rent for the hydrogen manufacturing site, etc.
How much can the cost be lowered through economies of scale, easing of regulations, etc.?
A future propagation model will be evaluated, assuming cost reductions through technological innovations and taking into consideration increases in project size, etc.
Examples of scenarios to be considered
(1) Large-scale wind power generation + locations where low/medium usage is concentrated
(2) Large-scale and remote-location wind power generation + transmission
(3) Remote islands
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Investigation of Future Project Feasibility (2030 Cost)
Building a supply chain of hydrogen manufactured with CO2-free methods can reduce overall CO2 emissions by at least 80% compared with a conventional approach.
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Investigation of Future Project Feasibility (CO2 Reduction)
-86%
-94%
Water electrolysis system TOSHIBA
Compressor Fueling truck Fuel cell forklift
This demonstration
project
CO2 emissions: 16.3 kg/day
Electric forklift
Com
parison (conventional)
CO2 emissions 119 kg/day
Gas station
Gasoline- powered forklift
CO2 emissions 266 kg/day
Delivery truck
Electric forklift
Gasoline-powered forklift
Renewable energy (wind power generation) Fossil fuel (diesel hybrid vehicle)
Power (grid power)
Grid power
Gasoline Fossil fuel (diesel vehicle)
Predicted 250 days of activity per year
CO2 emissions: Zero CO2 emissions: Zero
CO2 emissions: Zero
Hydrogen transport distance: Around 50 km to Kawasaki and 10 km to Yokohama, for a total of 60 km. Transport vehicle CO2 emissions per vehicle (source: Ministry of Land, Infrastructure, Transport and Tourism): 0.272 kg-CO2/-km ⇒ CO2 emissions: 16.3 kg/day
Power consumption: 216 kWh/day CO2 emissions per unit of power: 0.551 kg-CO2kWh ⇒CO2 emissions: 119 kg/day
Gasoline consumption: 114 L/day CO2 emissions per unit of gasoline: 2.322 kg-CO2/L ⇒CO2 emissions: 265 kg/day
Gasoline delivery distance: 5 km from the nearest gas station, transport truck fuel efficiency: 10 km/L CO2 emissions per unit of light oil: 2.619 kg-CO2/L ⇒CO2 emissions: 1.3 kg/day
Gasoline usage 1.9 L/h-vehicle x 5 h x 12 vehicles =114 L/day (data by Toyota L&F Company)
Demonstration Project Schedule
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Note: Factors such as future discussions with the Ministry of the Environment may cause changes to the demonstration details and implementation plan.
FY2015 FY2016 FY2017 FY2018
Project overview Basic design, prototype, feasibility study
System building Test run
System building (cont.) Demonstration system
introduction, operation start
Operation Evaluation and impact study
Hydrogen manufacturing
Hydrogen storage
Hydrogen transport
Secondary batteries
Hydrogen utilization
Construction at Hama Wing site
Demonstration operation phase
Design/manufacturing preparation
Receiving/transforming equipment modification, distribution panel construction
Tank/compressor construction
Demonstration operation
Design/manufacturing preparation Demonstration operation
Manufacturing of system No.1
Hydrogen manufacturing stabilization system construction
Ordering Foundation, infrastructure, and office construction Demonstration operation Plan/design Recovery
Demonstration operation Water electrolysis construction
Manufacturing of system No.2
Demonstration operation (one system) Demonstration operation (two systems)
Two forklifts Ten forklifts
Demonstration operation (two facilities) Demonstration operation (four facilities)
Test run Full-scale run
Start of water supply Electricity supply from Hama Wing
Design/manufacturing preparation
Toward the realization of a low-carbon hydrogen society
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