DuraDemo – sivuvety energiaksi polttokennolla, hanke-esittely

Jari Ihonen, VTT Timo Keränen, VTT

219.11.2012

Contents of the presentation

Project participants and funding

Motivation for the project

Project goals

Structure of the project

Some details of the 50 kW unit

319.11.2012

Project participants and funding2-year TEKES funded project supporting Demo2013, started April 2012

Total budget 1,5 M€10% industry70% Tekes20% VTT

Following industries are involved in the projectIndustries with interest for stationary applications Working machine industryCompanies, that are in the value chain of future Finnish company

A parallel business development project is ongoing in Äetsä/Pori coordinated by Prizztec

419.11.2012

MotivationIn 2012-2013 TEKES FC programme projects should support Demo 2013 industry projects

Durability demonstration of PEMFC technology is important for working machine industry

In Finnish chlor-alkali industry need for large PEMFC systems for the use of by-product hydrogen – near term market

VTT has sufficient knowledge to demonstrate PEMFC systems using by-product hydrogen from e.g. chlor-alkali industry

Peak power / reserve power (with low capital cost) increasingly interesting as share of solar/wind electricity increases

2 H20 + 2 NaCl –> 2 NaOH + H2 + Cl2

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Side product or industrial Hydrogen in Finland

Side product now:Kemira Chemicals, Äetsä, Kuusankoski, Joutseno

Total c.a. 18 000 ton/a (0,6 TWh)Eka Chemicals, Oulu ?

Side product future:Outotec process for the sulfuric acid?

Production from hydrocarbons now:Neste Oil

- steam reformation from natural gas- use in oil refining a. 108 000 ton/a

Production from hydrocarbons future:CO containing industrial gases from (steel/metal & power) industryHydrogen from biogas/NG, hydrogen from biomass

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How many units / year to be be served with 18 000 tons of H2 ?

A car consumption 1kgH2/100km20 000 km/a 200kg 90 000 cars

ORA bus consumption 8kgH2/100km40 000 km/a 3 200 kg 12 500 buses

ORA family house typical power consumption 18 000 kWh/aH2 3,0 kWh/Nm3 (lower heating value)18 000 ton H2 = 199,8 MNm3 33 300 houses

Value of hydrogen replacing peat in heat production: 20-25 €/MWhValue of hydrogen in small scale vehicle demonstration up to 500 €/MWh

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Example case: Nedstack / AkzoNobel Pilot Plant at Delfzijl

Source: Middelman,Verhage,Manders. ”Power Generation with PEM Fuel Cells at a Chlor-Alkali Plant”, 2008 FCSE Phoenix, Arizona.

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The use of by-product hydrogen power plant for frequency regulation, spinning reserve, FRR and FFR

Characteristics of H2-PEFC power plant Very high part load efficiency (peak at about 20% of nominal power)

Safe operating down to about 10% of nominal power is possibleExtremely high ramp rate

Regular (20-60% in a 5 seconds, 20-100% in 30 seconds)Emergency (20-60% in a second, 20-100% in 3 seconds)

Capital cost per kW (excl. grid connection) expected to be very low (<300 €/kW)Overrating (130-150%) short terms possible inverter overrating for short terms also possible (like in ABB PCS100)

DC-AC connection using an inverterConnection of supercapacitors in the same DC bus possible

Even faster ramp rates and more peak power achievable leading to much less €/kW cost for

Voltage stabilization possible due to reactive power control

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Flow of hydrogen like water in a river- some similarities to run-of-river hydro plant

Flow fluctuates and this determines power plant sizeHigher capacity gives more regulation power

More capacity can be added later as value for regulation power increases

Available capacity can be used as fast/emergency reserve Short term (minutes) increase in power does not require a storage

Pressure tank corresponds dam in the riverSmall pressure tank allows intra-hour regulationLarger pressure tank allows intra-day regulation

PEFC plant can (with ultracapacitors) have even faster ramp rates than hydro power plants and have no legal restrictions

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Value of regulating and reserve power

Spinning frequency reserve (taajuusohjattu käyttöreservi)Capacity compensation 11,97 €/MW,hEnergy compensation: hourly regulation upPrice in increasing

Spinning disturbance reserve (Taajuusohjattu häiriöreservi)Capacity compensation 2,80 €/MW,h

FRR (Automatic Frequency Restoration Reserves) new product in Nordic energy market

Fast Frequency Response (FFR) might be a new product in the Nordic market in the future, introduced already in Ireland

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Optimal use of industrial by-product (or refinery) hydrogen for power (and heat) production

PEFC power plant capacity will be inexpensive (< 300 €/kW), but when?Electricity price fluctuation will increase – due to renewablesTSO grid fees (kantaverkkomaksut) will increaseRegulation/reserve power (capacity) value will increase (how much?)

Key issues:Value of other uses for hydrogen (by-product) and value of heatCost of NG -> cost of hydrogen (refinery)

“free” capacity and storageHydrogen storage cost and possibility (safety, regulations)Life-time of stacks and system components

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Project goalsDemonstration of PEMFC technology in a stationary application using process by-product hydrogen as fuel

A 50kW PEMFC power plant will be builtSimulation tools delivered in a previous TopDrive-project will be utilized and further developedFuel cell system BoP and power electronics components will be characterized in laboratory environmentQuality of hydrogen and how it affects fuel cell performance will be studied

Identification of business opportunities for PEMFC technology in Finland

Training of experts in fuel cell technology and system integration

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Structure of the projectA 50kW PEMFC stationary power plant (WP1)

Designing and building the system5000 hours of operation at Äetsä on by-product hydrogenDemonstration as back-up power source at Vuosaari harbour

Simulation of PEMFC and hybrid electric systems (WP2)PEMFC system level modeling

BoP component dynamics, 0D stack modelHybrid electric drivetrain modeling

Energy storages, Electric machines, Vehicle dynamicsSoftware used: Matlab/Simulink, Thermolib, SimPowerSystems

Fuel cell system BoP and power electronics components (WP3)Synergies between SOFC and PEMFCEvaluation of new components

Quality of hydrogen (WP4)By-product hydrogen quality at ÄetsäEffects of impurities on PEMFC

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Structure of the DuraDemo project

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50kWe PEMFC featuresÄetsä site characteristics

Purified industial by-product hydrogen fuel supplyWaste hydrogen purge back to process product pipelineProcess heat utilized in facility heating

System integrationAssemby inside ISO container s(2 x 10 ft.)Compliant with existing FC and electric installation standards

IEC 62282-3-x, ISO/TR 15916, EN 50438, IEC 60664-1, IEEE 1547 etc.Stack & system characteristics

350-600VDC, 0-150A (~52kWe)50-60% stack efficiency7 stack modules (about 500 cells total)

Power electronics characteristicsSolar inverter + isolating transformerAnti-islanding capable0,4kV output45-47 kWe output to grid*

*: Assuming 7,5% FC BoP losses & 95% converter efficiency

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Physical dimension in 10 ft containers

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Power electronic solution

Inverter by ABBUPS solution by (Elcon)

3-phase UPS (Pyramid) Protection by diodes between inverter and FC system

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Control system

PLC-moduls (Schneider Premium)

CAN-trafic CVM – PLCProfibus-connection to inverter

Remote controlledMonitoring & control room (THT Control)

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Siplified system design

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Air supply system for the cathode

Main componentsHumidifiers(Permapure)Compressor/motor (Ogura / ABB)Air filters (Freudenberg)Humidity sensors (Vaisala)

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Anode gas (hydrogen) supply system

In-house bubble type humidifier Other main components

Pressure reducer (RHPS)Sensors (pressure, humidity, hydrogen concentration )Valves (safety, purge)

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Cooling system

Radiatator based solution Liquid to air

Components Water pump (Iwaki)Ion exchange filtersSensors (conductivity, pressure, temperature) Radioator Lpt-anturit

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BoP-integration and assembly to container

Stacks and main components are installed in the frame, which is rolled in the containerSolution is not designed for outdoor conditions in the wintertime

No anti-freezing measuresEasily movableProtection against theft/vandalism

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Part of the project is a study for a fuel cell business potential in Finland (MSc. Thesis work)

Potential commercial near-term markets for fuel cells in FinlandReview of commercial niche markets and on-going demonstrationsExpert interviewsIdentification of domestic opportunitiesEvaluation of technology readiness

Consideration of identified business cases and possible new business models

Possibilities beyond domestic markets?Thesis work started in Q4/2012