Natural Gas to HI.pdf

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8Development of a High-Efficiency

Natural Gas-to-Hydrogen Fueling System

Presented by:

William E. Liss, GTI and Ralph Rackham, FuelMaker

October, 2001



Hydrogen Supply & Infrastructure

Natural

Gas

Small/Onsite

Methane

Reforming

Hydrogen

CoalBiomass

Large-ScaleGasification

Gasoline/Diesel On-Board Reforming

MethanolOn-Board

Reforming

PrimarySource

TransformationProcess

Onsite

H 2 Stations

Over the Road to H

2 Stations

Onboard

Onboard

Delivery/Use

Large-Scale

Methane

Reforming

Over the Road

to H 2

Stations

Water Electrolysis

(electricity,

solar power)

Onsite

H 2

Stations



DOE/GTI Hydrogen Fueling Program

High-Efficiency Onsite Steam Methane Reforming

$4.2 million program Partners: FuelMaker Corp., Tulsa Gas Technologies, others

Address:

High-efficiency steam methane reforming Innovative fuel processing

Appliance-quality hydrogen compression

Advanced fuel dispenser

System modeling (performance, economics)

System control and integrated product development for

reliability and cost

Leverage substantial compressed gas vehicle experience



Natural Gas Reforming Extensive Experience

Reforming Natural Gas (andother fuels) to Hydrogen

40 years of fuel cell experience

Current PEM System for

Stationary Market Mosaic Energy

Natural Gas

Naphtha

Modifying Design For H2 Generation

Mosaic Energy – Early

PEM prototype on Natural Gas

Mosaic Energy PEM fuel cell in Tokyo

running on reformed naphtha



FuelMaker – Compact

TSA/PSA Unit

Gas Processing Develop Compact and

Regenerable System

Remove water and carbondioxide (CO2)

Based on FuelMaker's currentDryer technology

Integrated columns, manifold,valves, heaters, and controls

Evaluate membranes anddessicants

Integrate Compression andDryer/Purifier Systems IntoOne Appliance



Gas Compression Compressor Design/Development

Modifications for reformate stream,increased operating pressure, andintegration of the Dryer/Purifier

Motor Design and Selection Evaluate AC, DC, variable speed

operation

Controls Design 7500 psig operation, cost/reliability

impact

Electronics and Software Operation of compression,

Dryer/Purifier, and dispenser

Build Benchscale Prototypes Extensive testing and modifications to

attain flowrate/power/pressure targets

Concept Based on Current FMQ- 10 NGV Product



Gas Storage & Dispensing

GTI Will Develop “Hydrogen

AccuFill” System Conduct Low, Mid, and High-

Temperature Fill Tests In GTIEnvironmental Chamber

Use First PrincipleThermodynamic Model(CHARGE) To Develop FillingAlgorithm

Patented Approach for Accurate

Fast-Fill Dispensing

Address Fast-Fill TemperatureRise

Testing in GTI’s 3000 ft 3 Environmental Chamber

(High and Low Temp.)

Full Size 7000 psig H2 Cascade(11,000 scf)

Evaluate on Three Different H2 VehicleCylinders

(steel, aluminum, plastic liners)

Precision Instrumentation

-100

-80

-60

-40

-20

0

20

40

60

80

100

0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00

Time (min)

T e m p e r a t u r e ( F )

Cylinder

Receptacle

Outlet

Supply Cascade

Nozzle In

Chamber



Hydrogen Dispensing

Work With Leading High-Pressure Dispenser Manufacturer Public-Style H2 Dispenser With

TGT

FuelMaker to produce privatefast-fill system

Modify CNG Dispenser for High-Pressure H2

Address Range of Issues: Meter availability, display units

for public sale, high-pressurehose availability, suitability for Group B service

Incorporation of AccuFill

Algorithm

Tulsa Gas Technologies

CNG Dispenser Sponsored by GTI



System Modeling

Economic and Systems AnalysisOperating Parameters

Station Output kg/day 50.0 427 scf/kg

Compressor Output scfm 20.0

Gas Cost $/Mcf 3.782Reformer Flow Ratio (H2 out/NG in) 1.99Reformer Burner Flow Fraction 46.9%

Reformer Gas Consumption scfh 603Reformer Utility Gas Cost $/hr 1.07Reformer Processed Gas Cost $/hr 1.21

Electric Cost (nom/L/H) $/kWh 0.07 0.04 0.15

Electric Demand Cost (nom/L/H) $/kW/mo. 20 0 40

Total Electric Load kW 16

Utilization

Initial Utilization 0% 100.0%Growth Rate Factor 2/.01 1

Max. Utilization 100.0%Years to Max. Utilization 100% 4

Operating Days per Year 6500 365 Operating Hours per Day 18

Financial Parameters

Fueling Station Useful Life yrs 10Working Capital % of ∆ inc. 2.6%Salvage Value of orig. 0%Depreciation Method M

Real Discount Rate annual 8%Marginal Tax Rate 34%

Hydrogen Reformer Fueling Station Economic Model

Hydrogen Fuel StationEconomic Model

Builds on extensive NGVexperience

Features:

Variable & probabilistic

costs Variable utilization and life

Tax, incentive, and subsidyeffects

Monte Carlo Functionality

Use HYSIS for ProcessModeling



Life-Cycle Cost per Gallon LNG

2.74

584

6,074

95,477

13,600

5,477

234

0.17

42,739

4.4

5.02

916

14,388

112,254

26,400

16,838

366

0.36

51,127

7.6

$0.60 $0.70 $0.80 $0.90

Gas Cost $/Mcf

Engine drive: daily check cost

Engine drive: major rebuild cost

Gas cleanup: capital cost

Engine drive: major rebuild interval

Misc. capital cost

Compressor: daily check cost

Electric: usage cost

Construction cost

Oil filters and housings: replace filter

Dow nside

Upside

Monte Carlo Simulation Results

0

0.01

0.02

0.03

0.04

0.05

0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30 1.40

$/gallon

P r o b a b i l i t y

Example – Small-Scale Natural Gas Liquefier

Economic Analysis

Sensitivity Analyses

Identifies major station costelements thatinfluence life-cyclecosts

Monte CarloSimulations

Yield a distributionof expected life-cyclecosts

Range of probable topossible costs



Targeted Benefits: Systems & Subsystems

REFORMERS PURIFIERS COMPRESSORS DISPENSERS STORAGE

SYSTEM INTEGRATION

Natural gas reformerssuitable for H2 fuelingstations andstationary fuel cells(from GTI/MosaicEnergy).

Liquid fuel-basedreformers for hydrogen fuelingstations andstationary fuel cells(from GTI/MosaicEnergy and IHI).

Cost effectivestrategies for naturalgas cleanup, shiftconversion, and COremoval (from GTI/Mosaic Energy).

Highly innovativeproduct strategies for post-reformer water and CO2 removal(from FuelMaker).

Family of appliance-quality products for H2

fueling (FuelMaker).

Units ranging fromindividual home

fueling systems tointegrated designs for larger stations.Suitable for use withtime fill or fast fillvehicle applications.

Compressors suited

for use with reformer or electrolyzer-basedequipment(FuelMaker andStuart Energy).

High-qualityHydrogen Dispenser for public fueling(from Tulsa GasTechnologies).

Integrated dispensingstrategies (withcompressor appliance) for low-cost onsite H2 fueling(from FuelMaker).

State-of-the-Art fast

fill algorithm for addressing hydrogenunderfill issues (GTIand FuelMaker).

Demonstratedhydrogen cascadestorage system for hydrogen fuelingstations (NorrisCylinder Company).

ComprehensiveHydrogen FuelingStation design (GTI

and FuelMaker).

Strategies for integration of reformer, purifier, andcompressor operation(GTI and FuelMaker).

Computer program -CASCADE - for sizingH2 compressors andcascade storagesystems (GTI).

Technology transfer

to interested partnersin the NGV FuelingStation business(GTI/Blue Energy).



Program Tasks & ScheduleDescription

High Efficiency Fuel Reformer Development

Reformer Design Topical Report

Reformer Bench-Scale R&D Topical Report

Hydrogen Fast Fill Characterization

Fast Fill Conceptual Design Topical Report

Fast Full Bench-Scale R&D Topical Report

Hydrogen Dispenser Development

Dispenser Conceptual Design Topical Report

Dispenser Bench-Scale R&D Topical Report

Hydrogen Compressor Development

Compressor Conceptual Design Topical Report

Compressor Bench-Scale R&D Topical Report

Hydrogen Fuel Purification Development

Fuel Purification Conceptual Design Topical Report

Fuel Purification Bench-Scale R&D Topical Report

Hydrogen Fueling System Design and Economic Assessment

Primary Economic Assessment Topical Report

System Design and Secondary Economic Assessment Topical Report

System Prototype Delivery for Field Testing

System Prototype Delivery for Third-Party Validation

Management and Reporting

General Milestones/Deliverables

Project Plan

Quarterly Reports

Phase I Report

Phase II Report

Draft Final Report

Final Report

Project Kick-Off Meeting

Internal Project Review Meetings

Annual Reviews at DOE

Presentation of Final Results

Technical Paper Presentation

A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S

2002 2003 2004



Summary Hydrogen and Natural Gas…Strong Connectivity

Program Will Build On Substantial NGVExperience

Work with leading suppliers to this industry

Project Slightly Behind Schedule

Contracting issues

Expect Range of Products To Result From ThisProgram

Hydrogen compressors, dispensers, filling algorithms,fuel clean-up strategies…



Contact Information

William E. LissGas Technology Institute

1700 S. Mount Prospect Road

Des Plaines, IL 60018Phone: 847-768-0753

FAX: 847-768- 0501

E-Mail: [email protected]

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