a vision of a hydrogen economy - university of waterloochemeng.uwaterloo.ca/mfowler/hydrogen retail...

A Vision of a Hydrogen Economy

Design of a Hydrogen Power Park2005 H2U Design Contest National Hydrogen Association, U.S Department of Energy, and ChevronTexacoTeam Members: Allison Mendes, Shirley Leung, Hani Fadali, Gordon Graff, Bryan Icyk, Bartosz Lomanowski, Abhay PatelAdvisor: Michael Fowler

Group 16: Design of a Hydrogen Power Park

Project Goal

To design a feasible, innovative & safe Hydrogen Power Park that will refuel fuel cell vehicles and produce electricity

Team VisionTo generate greater demand for aHydrogen Fuel Economy


Today’s Topics

The TeamPark requirements Park Design Safety EconomicsEnvironmental AnalysisMarketing Plan


Human Resources

The Team!

Allison Mendes

Chemical Eng.Shirley Leung

Chemical Eng.

Gordon Graff

Architect

Bartosz Lomanowski

Mechanical Eng.

Hani Fasali

Electrical Eng.

Bryan Icyk

Business/Marketing

Abhay Patel

Chemical Eng.

Dr. Michael Fowler, P.Eng.

Faculty Advisor

Chemical Eng


Your Energy Source


Park Requirements

The park will commence service in 2010 for a ten year service life

Generated and stored hydrogen on-site Increase capacity from 50 kg/day to 250 kg/day at 5 kg/carMaximum footprint: 21000 sq ftProvide a minimum of 100 kW of electrical power using green energyUse commercially available equipment


Park Design – Waterloo is A Perfect Location !

Become one of the pit stops along the Hydrogen Corridor between Windsor-MontrealAffiliation with the University of Waterloo

Education tool for university researchEncourage evolution of hydrogen technology

Location:

Waterloo Research and Technology Park


Park Design – 2D Site PlanFootprint: 21000 sq ft


Hydrogen Development Incubator

Aims:To develop and promote hydrogen production and distribution

Enhance the developmental and research efforts by serving as a ‘think tank’


Public Education CentreLocated in the Power Park for students and public to learn about hydrogen production and its advantages

Features of Educational FacilityCut-away models of hydrogen vehicles and equipments Posters


Park Design- Renewable Feed Source

Renewable and relatively cheap feed sourceThe process feed will be composed from a landfill gas from the Waterloo Landfill site in Southwest OntarioLandfill gas cost $0.045/m3 compared to $0.315/m3 for Natural Gas!

COHOHCH +↔+ 224 3Waterloo

Power Park

H2

Waste Disposal Site

Methane


Park Design – 3D Rendering [Side View]


Park Design – 3D Rendering (Top View]

Group 16: Design of a Hydrogen Power ParkEquipment 3D

Park Design – Process Equipment (3D)


Park Design – Expansion in 2016


Process Flow DiagramFeed Gas

Zinc-OxideTank

Pre-Reformer

Primary Reformer

Hydrogenation Reactor

Compressor

ZnS

Municipal WaterAir

SOFC

H2 Product

Electricity Produced

Dispenser

Bank #25014.7 psi

Bank #16264.7 psi

LegendGate Valve

Screw Down ValveMulti-Way Ball Valve

Control ValveSpring Loaded Pressure Release Valve

Buffer Bank #35014.7 psi

Ball Valve

H2 to Vehicles

Splitter / Mixer

Heat Exchanger

Air

Priority Sequencing System

PSA

Offgas

Check Valve

Generator Set

Pressure VesselsPressure Vessels

Pressure Vessels

•Conditioned landfill gas (≈ natural gas) is supplied by pipeline to power park

•The gas is reformed, compressed and stored onsite at high pressures and finally dispensed to FCVs.

•Electricity is generated by a 125 kW SOFC using a mix of partially reformed gas and PSA waste gas.


Park Design- Rational for Equipment Selection

Pre-reformer - Hydrogenics Corp.Increases % conversion of methane to hydrogen in SMR due to increased steam to carbon ratio (S:C).Act as a sulphur guard (extends life of expensive SMR & SOFC)

SMR (Steam methane reformer) - Hydrogenics Corp.Significantly less expensive than an electrolyserBased only on energy and capital costs:• electrolyser $555 US/kg• reformer $1.6 US/kg

PSA (Pressure Swing Adsorption) - Hydrogenics Corp.Purity of product stream yields 99.95% H2


Park Design- Rational for Equipment Selection125 kW Solid Oxide Fuel Cell (SOFC) – Siemens Westinghouse Power Corp

Lowest emissions of any power plant using natural gasIncorporates a power conditioning system to convert DC to ACHigh electrical efficiency even at part load

2-Stage Diaphragm Compressor - Products Industries Inc.Completely isolates process gas (pure H2) from contamination Relatively low maintenance


Park Design- Rational for Equipment SelectionCompressed Gas Storage System - CP Industries

3 storage banks under 2 different pressures Cascade filling system to minimize hydrogen storage capacity1-day buffer storage capacity (load flexibility)

H2 Dispenser - Fueling Technologies Inc.One dispenser with a single, side oriented, nozzleProvides temperature compensated fills (safety feature)

Bank1: 4x764.6 L (6264.7 psi)

Bank2: 6 x 968.4L (5014.7 psi)

Bank3: 14x 968.4L (buffer)


Park Design-Electrical System

A safe, realistic and practical design that adheres to all applicable codes and standards SOFC operates in parallel with the grid• Reduce the need to purchase electricity• Supplies critical site power in case of power

outage• Selling power to grid is unprofitable

100 kW generator set for stand-by operation in case of an outage on the supply utility system


U tility g rid

U tility d is c o n n e c tin g m e a n s

U tility b re a k e r U tility

S ys te m

D is c o n n e c tin g m e a n s - u tility

M a in e n tra n c e b re a k e r

T yp ic a l B u ild in g L o a d s

B re a k e r

T ra n s fo rm e r – 3 0 0 k V A P rim a ry : Y -, 8 k V , 3 p , 4W S e c o n d a ry : Y -, 4 8 0 V , 3 p , 4W

B re a k e r (s yn c h ro n iz e d )

F u e l C e ll

D is c o n n e c tin g m e a n s - g e n e ra to r

F C

M R e v e n u e M e te r

L o c a l B u s

D is tr ib u tio n P a n e l

T ra n s fo rm e r – 3 0 k V A P rim a ry : Y -, 4 8 0 V , 3 p , 4W

S e c o n d a ry : Y -, 2 0 8 V , 3 p , 4WB re a k e r

P ro c e s s a n d S p e c ia l L o a d s

G G e n e ra to r S e t

B re a k e r (s yn c h ro n iz e d )

B re a k e r (s yn c h ro n ize d ) P a ra lle lin g S w itc h b o a rd

Interconnection Diagram of Power Production Sources with Loads


Electrical RequirementsElectricity Consumption

0

50

100

150

200

20 0920 1020 1120 1220 1320 1420 1520 1620 1720 1820 19

Year

kW/d

ay

050100150200250300350

kg/d

ay

Daily Typical Loads (kW)

Daily Process Loads (kW) -ModerateTotal Daily Electricity Consumptionfrom the Grid (kW) - ModerateHydrogen Sales (kg/day)

SOFC: Able to produce 3000kWh/day and will only produce energy as required.

As the energy consumption increases beyond 3000kWh/day, the difference is drawn off the local power grid.

The SOFC produces less CO2 emissions than grid power.

SOFC: 440g of CO2per kWh

Grid: 453g of CO2 per kWh


Safety Considerations in the Park Design

4 major failure modes and their preventive measures:

1. Human Erroradequate employee trainingvisible warning signs and instructions

2. Gas Leakagesbuilt according to standards, regular inspections

3. Equipment Failurescheduled maintenance as suggested by manufacturers

4. Terrorism security cameras, card-accessed entrances


Safety Considerations in the Park Design

When there is hydrogen Fire /Leakage:

Infrared/UV sensors, smoke detectors, flow sensors audible alarms + red flashing light + emergency fail-safe shutdown emergency dispatcher fire department


Hydrogen Properties 1FlammableNon-toxicOdourlessColorless gas Small molecular size • prone to leakage

Compare to natural gasDiffuses in air 3.8x fasterRise 6x faster

Invisible flame (unless coloured by impurities)• significantly less radiant

heat than hydrocarbon fire

• reduce the risk of secondary fires

• but less warning as one approaches the invisible flame


Hydrogen Properties 2Combustion

Hydrogen → water vapourNatural gas (incomplete combustion) → toxic CO & CO2, water

Flammable mixtureAs long as ventilation is adequate, the probability of hydrogen forming a flammable mixture with air is very low

LeakLarge leak → flammable cloud + ignition source →fire/explosion• strict prohibition of open flames (e.g. smoking) and

cell phone usage


Hydrogen vs Natural Gas vs Gasoline

Flammability limits and ignition energy of H2, CH4 and gasoline with air

Flammability range of hydrogen is 7 times wider than methane


Safety Analysis

Safety analysis at conceptual stage: • opportunity for inherently safer design solutions• more cost-effective to operate the power park

Reduce chance of:• process safety related incidents • downtime and financial losses• losing public confidence

Advantages


HAZOP (Hazard and Operability)

HAZOP MethodologyLogical & systematic approach for identifying potential hazards Creates deviations from the process design intentOnly warrants qualitative analysis; not quantitativeConventional group approach discarded• Lack of experienced human

resources

Safeguards/MitigationsConsequencesCausesDeviationParameterProcessSection

GUIDE WORDS: more, higher, longer, less, lower, shorter, as well as, also, part of, reverse, other than, sooner, lower. ….


HAZOP Results SummaryEquipment of the highest risk:

Dispenser

Human error preventions:Trained operator to refuel vehicles Clear labels / instructions: • Manual emergency shutoff valves labelled with direction of

turning• Pipelines labelled with direction of flow


HAZOP Results Summary

Sparks generation preventions:Permanent bonding and grounding of equipmentsGrounding of person doing maintenance workUse tools that do not generate sparks

Sabotage/terrorism preventions:Surveillance/security systemRemote manual emergency shutdown system


High Risk Situations1. Maintenance, start-up and shut-down of equipment

• Venting or bleeding device to depressurize gas before dismantling• Start-up procedures (e.g. purging with an inert gas)

2. Control system fault • Cause: grid power outage

• SOFC & generator set can supply power to control system. • Cause: virus/hacking

• Anti-virus and firewall softwares• Watchdog timer to monitor

status of the control computer


Essential Safety ComponentsInstruments

Flammable gas detectorsSmoke detectorsUV/infrared hydrogen flame detectors Manual + automatic safety shutoff valvesPressure relief valvesGrounding/bonding

Systems:Redundant fail-safe shutdown (automatic and manual) Emergency ventilation Emergency powerSecurity


Economics – Purchase CostsTotal Purchase Cost$6,458,648 US

Dispenser $62,988Compressor $97,660Storage System $198,000100 kW SOFC $200,000Primary Reformer (2) $1,600,000Pre-Reformer (2) $1,400,000Control System $200,000Hydro-desulf. unit (2) $200,000Zinc-Oxide Bed (2) $200,000PSA $50,000piping, etc. $50,000Land $1,000,000Building $1,000,000Construction Costs $200,000


econ

Economics - ProfitabilityBreak-Even Point (Moderate Scenario)

-$8,000

-$6,000

-$4,000

-$2,000

$0

$2,000

$4,00020

09

2010

2011

2012

2013

2014

2015

2016

2017

2018

2019

Year

Thou

sand

s of

US

D

Annual Net Income Aggregate Annual Net Income

Revenue vs. Cost (Moderate Scenario)

$0$1,000

$2,000$3,000

$4,000$5,000

$6,000$7,000

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019Year

Thou

sand

s of

US

D

Total Annual Revenue Total Annual Cost

Break-even point: 2018

Payback period: 9 years.

Total revenue: $26.9 M•Mostly from hydrogen sales ($22.6 M, $53.38/kg)

•Other sources: convenience store, carbon emissions credits

Average production cost of H2: $33.95/kg


Economics – Cost breakdownTo t al C o st B reakd own

Tot al operat ing expenses

46%

Tot al COGS (Mid Level Scen.) 8%

Tot al Capit al Cost s46%

Operat ing C o st s B reakd o wn

Depreciat ion35%

Miscellaneous 10%

Maint enance 19%

Legal 4%

Insurance 10%

Labour12%

Market ing10%

Total capital costs: $9.1MPurchase costApplicable taxes (15%)Installation and transportation (2% of purchase cost)

Operating costs: start at $846Kin 2010 and rise with the projected rate of inflation

Average cost of goods sold: $138K• Electricity consumption• Feed gas• Convenience store


Environmental Analysis

SMR PSA

SOFC

Pre-Reformer

Landfill Site

FCV

Break in SystemCO2 emissionsElectricity

YES Power Park

Comparison of CO2 Emissions

0

100

200

300

400

500

600

Gas60

kg H

2/day

70 kg

H2/d

ay80

kg H

2/day

100 k

g H2/d

ay12

0 kg H

2/day

145 k

g H2/d

ay18

0 kg H

2/day

225 k

g H2/d

ay27

0 kg H

2/day

300 k

g H2/d

ay

Process

Avg

. CO

2 Em

issi

on (g

CO

2 /m

ile)

Vehicle operation

Production

Feedstockretrieval

As more hydrogen is produced per year, the average grams of CO2per mile decrease.

The major CO2emissions are localized at the power plant which makes CO2capture achievable.

Adopting hydrogen process reduces automobile-related emissions by at least 40%


Marketing PlanTargets1. Fuel cell vehicle owners:

i. Businesses operating FCV fleetsii. Early adopters.

2. Waterloo community

Marketing StrategiesPromote and support early adopters (e.g. ChallengeX Vehicle)Position hydrogen as an attractive fuel source (e.g. use of education center)Accelerate commercialization of the hydrogen economy

Looks and behaves like a gasoline stationAlign the park with the Toronto Hydrogen VillageLocated next to a Hydrogen Development Incubator


Marketing Plan - Implementation

The launch of the marketing campaign will corresponds with the 2010 Winter Olympic Games in Vancouver, British Columbia

Anticipated that hydrogen and related technologies will receive a significant amount of national and international exposure


Summary More than just a hydrogen refuelling stationDevelopment Incubator + education center to promotes the adoption of hydrogen technologyFeasible, innovative & safe Reduce and localize emissionsMarketing plans to achieve hydrogen acceptance


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