hydrogen technical analysis: energy station · revenue from power sales help overall economics in...

Hydrogen Technical Analysis: Energy Station

TIAX, LLC1601 S. De Anza BlvdCupertino, California95014

TIAX Ref: D0038DOE Ref: DE-FCO4-02AL67602

2003 Hydrogen and Fuel Cells Merit Review Meeting

Berkeley CA

May 19-22, 2003Work in Progress

041003/SL/PT/D0035 FC Phase III Summary_draft.ppt 1

Introduction Background

Hydrogen energy stations could substantially enhance competitiveness of on-site hydrogen production in the near and long-term.

• Key hurdles to the development of a hydrogen infrastructure are:Long-term cost of hydrogenTransition cost to implement the minimum infrastructureEfficiency of hydrogen production in on-site stations

• Combining hydrogen production with power production could provide synergy that could make both parts competitive:

Revenue from power sales help overall economics in early yearsImproved economy of scale from larger systems reduces specific system costSynergy in storage system allows for cost reduction and low-cost back-up and rapid start-up for power generation systemIntegration can increase overall efficiency slightly


Introduction Goals and Objectives

The purpose of this study is to evaluate the issues surrounding the establishment of a hydrogen energy station.

• Evaluate combined fuel cell power/hydrogen Energy Stations

• Assess integration with buildings and potential for cogenerationAnalyze economics of energy station configurations

• Identify potential fleets for vehicle operation

• Establish partnerships for hydrogen fueling and power sales

• Identify barriers to hydrogen use

Characteristics Large (50-250 kW) Systems

Calendar Year Units2003

Status 2005 2010Electrical Energy Efficiency@ rated power % 30 32 40CHP Energy Efficiencyc@ rated power % 70 75 80Cost $/kWe 2500 1250 750Transient Response(time from 10% to 90% power) msec < 3 < 3 < 3

DOE Technical Targets: Integrated Stationary PEMFC Power SystemDOE Technical Targets: Integrated Stationary PEMFC Power System DOE R&D PlanDG Technical Barrier F: Heat Utilization. The low operating temperature of PEM fuel cell system technology limits the use of heat generated by the fuel cell, which represents approximately 50% of the energy supplied by the fuel. More efficient heat recovery systems and improved system designs and/or higher temperature operation of current systems are needed to utilize the low-grade heat and achieve the most efficient (electrical and thermal) distributed generation power systems.

DOE R&D PlanDG Technical Barrier F: Heat Utilization. The low operating temperature of PEM fuel cell system technology limits the use of heat generated by the fuel cell, which represents approximately 50% of the energy supplied by the fuel. More efficient heat recovery systems and improved system designs and/or higher temperature operation of current systems are needed to utilize the low-grade heat and achieve the most efficient (electrical and thermal) distributed generation power systems.


Introduction Hydrogen Energy Station Overview

The purpose of this study is to evaluate the issues surrounding the establishment of a hydrogen energy station

• Evaluate combined fuel cell power/hydrogen Energy Stations Analyze energy station systems with 50 kW PEMFCs that are suitable for installation in Federal buildingsAnalyze options for system components including direct hydrogen and reformate fuel cells and various storage, power production, and hydrogen usage configurationsDetermine costs and energy efficiency for different system configurations

• Assess integration with buildings and potential for cogenerationAnalyze potential for heat recovery from fuel cell/hydrogen production systemsIdentify potential for cogeneration in Federal building applications

• Identify potential fleets for vehicle operation

• Establish partnerships for hydrogen fueling and power sales

• Identify barriers to hydrogen use

• This study was supported by DOE contract DE-FC36-01GO11088


Introduction Tasks and Schedule

Prior to finalizing our analysis, we intend to obtain input from a range of potential stakeholders in both conventional and hydrogen fuel chains.

Task

1

2 Assess Public/Private Fleets

Analyze System Cost and Performance

Q1FY02 FY03

Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1

Evaluate Building Integration3Analyze Integrated Power and Fueling4Explore Public/Private Partnerships5Identify Barriers to Hydrogen Use5

Milestones

Identify Options for

Analysis

Draft and Final Report


Hydrogen Energy Station System Analysis Component Options

Several component choices are options for hydrogen production systems

Blower for SMR,Compressor for ATR,

C/E for ATR

Blower for SMR,Compressor for ATR,

C/E for ATR

50 kWeFuelCell

Reformer

Purif

icat

ion

Reformate FC,Direct H2 FC,

High pressure H2 FC

Reformate FC,Direct H2 FC,

High pressure H2 FCFC Coolant (heat)

Reformer exhaust (heat)PSA Tailgas (low Btu gas)

FC Coolant (heat)Reformer exhaust (heat)

PSA Tailgas (low Btu gas)

Cogen

Air HydrogenStorage

SMR (1 atm), SMR (10 atm), ATR (10 atm)

SMR (1 atm), SMR (10 atm), ATR (10 atm) PSA, Membrane,

Fluorinated HydridePSA, Membrane,

Fluorinated HydrideEliminate

compressor with 10 atm reformer

Eliminate compressor with 10 atm reformer

Natural Gas

Dispenser


Hydrogen Energy Station System Configurations

We applied filters to the matrix of possible configurations to select four promising technology combinations that meet various customer needs

Major ComponentsMajor ComponentsSystem AttributesSystem Attributes

Simple cogeneration

SMR, Reformate Fuel Cell, PSA

SMR, PSA, Direct Hydrogen Fuel Cell

SMR, Reformate Fuel Cell, Fluorinate metal hydrides

Air Compressor, ATR, PSA, Direct Hydrogen Fuel Cell

Small scale purification

Conventional system

Lower cost fuel cell

Note: Cost are for high production volumes: 1,000+ units per year.Variations in operating profile are also being considered


Hydrogen Energy Station System Analysis SMR Configuration

A steam reformer results in higher hydrogen yield and simpler purification.

BlowerBlower

Purif

icat

ion

Steam-Methane Reformer

Direct H2 FCDirect H2 FC

Reformate compressorReformate compressor

50 kWeFuelCell



Cogen

Air HydrogenStorage

Natural Gas

Dispenser

SMR (1 atm)SMR (1 atm)PSAPSA

An ideal system would include a high pressure reformer and eliminate the reformate compressor.


Hydrogen Energy Station System Cost System Analysis Piping and Instrumentation Diagram

A P&ID provides the basis for estimating costs for each configurations.

Pro pe rty of : T IAX LL C

16 01 S . D e Anza Bl vd.Ste. 10 0

C up erti no , C A 95 01 4

PRO PRIETARY INFORMATION

Piping and Instrumentation Diagram

H ydro gen F uelin g Stat ion - On sit e SMR w ith PSA

SIZ E DW G B Y DWG NO RE V

B S hy am V enk a tesh 80025-01 1b

SCAL E Not to S ca le 12 / 23/02 SHEE T 1 OF 1

CITY NG

AIR

WAT ER

CO2

HYDROGEN, 6000 P SIG

HYDROGEN, 6000 P SIG

S

S

S

S

S

S TACK

VE NT

M

S

F E601

P I620

P I621

P T650

P AH610 P DIT

655 T E611

I

P I622b

P I622a

P ICV675

S

PS V680

PS V681

PS V280

PS V284a

PS V284b

PS V284c

T IT210a

P IT250

D AC

T IT210b

P I220

P T252

S

P I222b

P I222a

P ICV275

P AH210

P I224a

P T25 6a

P I224b

PT256b

PS V288b

PS V28 8a

FI210a

F T220a

FI210b

F T220b

P DIT455

P I422b

P I422a

P ICV475

P DIT355

P ICV375

S

S

S

S

PS V282

PS V286

VE NT

P I322a

P I322b

FI301

T E311

T E4 11

M

P I623

S

B

A

4 3 2 1

B

A

4 3 2 1

VE NT


Hydrogen Energy Station System Analysis Operational Profiles

Daily operational levels for the FC and reformer will vary depending upon the target energy utilization strategy for the energy station si

X-Axis

BuildingLoad

Fuel ProcessorSized for Average

Loads Time

Fuel Cell StackOperated to Offset

Peak Loads AverageLoad

Power Demand and Related Fuel Cell Operational Scenarios

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Time of day

Pow

er D

eman

d

Station and building loadVehicle load

Load-following FC outputConstant reformer load

Hydrogen from reformer into FC

Excess hydrogen into Storage

Hydrogen from Storage into FC

Power Demand and Fuel Cell Operating StrategiesPower Demand and Fuel Cell Operating Strategies

te

♦ Base-loaded

♦ Electric load-following

♦ Heat-load following co-generation

♦ Peak shaving

♦ Back-up power

♦ Tailgas Exhaust to Boiler

Candidate Operating StrategiesCandidate Operating Strategies

Matching Building loads:Peak shaving: operating the fuel cell to reduce peak load on utility serviceAverage load: operate the reformer and fuel cell continuously to provide power to building Emergency backup: operate fuel cell on stored hydrogen and/or reformer during power emergencies


Hydrogen Energy Station System Cost Economic Analysis Cost Curves

In addition to technical performance parameters, the cost of components depends on production volumes.

$-

$100

$200

$300

$400

1,000 10,000 100,000 1,000,000Production Volume, units/year

Stac

k Fa

ctor

y C

ost,

$/kW

H2 PEMFC 450 mW/cm2

SR PEMFC 430 mW/cm2

Example 5kW system0.6 mg/cm2 Pt total

Example

PEMFC stack components will be used in both vehicle and stationary applications while markets for steam reformers will be more limited.


Hydrogen Energy Station Economics Production Volume Effects

The commercial success of any FCV, regardless of fuel, is tied to the cost of the fuel cell engine. Other fuel cell markets can help bring down costs.

10

100

1,000

10,000

2000 2005 2010 2015 2020

Stac

k C

ost (

$/kW

)

50,000 FCVs/yr

500,000 FCVs/yr and>100,000 stationary FCs

Gradual Vehicle Introduction

Fuel Cells in Multiple Markets

♦ Demonstration vehicles♦ Government fleets♦ Premium power♦ Combined heat and power♦ Commercial vehicle sales

♦ Demonstration vehicles♦ Government fleets♦ Premium power♦ Combined heat and power♦ Commercial vehicle sales


Hydrogen Energy Station Efficiency and Economics Fuel Cell System Architecture Options

There are two basic fuel cell architectures with multiple variations thereof

CO Cleanup

Fuel Processing

Fuel Cell Stack

Fuel

H2, CO2, CO,N2, H2O

“Conventional” -- Integrated Reformate Fueled PEMFC

Fuel ProcessorSubsystem

Fuel Cell Stack (~40% size reduction with H2 feed)

Fuel

Separate H2 Production & Purification Pure H2 Stack

H2Purification

CO2, CO,N2, H2O

H2 Storage

(1)

H2

This system strategy allows use of PEMFC stack technology that is likely to be available, and affordable due to early vehicle demos.


Hydrogen Energy Station System Analysis Fueling Capacity

Several trade-off options available between generating FC electricity and providing sufficient hydrogen for vehicle fueling

Fuel Cell Demand and Number of Vehicles Servedby a 50 kWe Reformer

0

10

20

30

40

50

60

70

0 200 400 600 800 1000 1200 1400Daily Fuel Cell Power (kWhe DC)

Max

imum

Use

able

Hyd

roge

n fro

m

Ref

orm

er O

utpu

t (kg

/day

)

50kWeReformer,Full LoadOperation

2 car fill-up

4 car fill-up

6 car fill-up

8 car fill-up10 car fill-up

12 car fill-up

Constraints on Vehicle Fueling and Fuel Cell Power Constraints on Vehicle Fueling and Fuel Cell Power Output Output -- 50 50 kWkWee ReformerReformer

Operating Strategies: Back up Peak Shaving Base Load

The reformer capacity, vehicle refuelings, and fuel cell can be matched for different operating strategies


Hydrogen Energy Station System Analysis Cogeneration Configuration

A simple cogeneration system uses the waste gas from an ATR to produce heat. Recovering the waste heat is simplified.

Purif

icat

ion

Auto-thermal Reformer

50 kWeFuelCell

Direct H2 FCDirect H2 FC

Eliminate reformate

compressor with 10 atm ATR

Eliminate reformate

compressor with 10 atm ATR

FC Coolant (heat), PSA Tailgas (low Btu gas)

FC Coolant (heat), PSA Tailgas (low Btu gas)

Air CompressorAir Compressor

Cogeneration

Air HydrogenStorage

Natural Gas

Dispenser

ATR (10 atm)ATR (10 atm)PSAPSA


Hydrogen Energy Station Technical Barriers Recognizing Environmental Benefits

With an energy station, optimal use of natural resources could be combined with zero emissions and extremely high reliability.

Over 90% reduction of criteria pollutant emissions

Enhances grid reliability through energy storage and fuel cells with few moving parts

Reduced greenhouse gas emissions

Managed technical risk through use of hydrogen fuel cells rather than conventional stationary fuel cell systems

Facilitates implementation of fueling infrastructure

Lower cost through shared components for vehicle fueling and stationary fuel cell power

Annual Greenhouse Gas Emissions

0100200300400500600700

Gasoline Vehicle, Grid Power Energy Station

GH

G E

mis

sion

s, to

n/yr

VehicleHeatPowerPower/Heat

Over 50 % Reduction

Annual Criteria Pollutant Emissions

020406080

100120140160180

Gasoline Vehicle, Grid Power Energy Station

Crit

eria

Pol

luta

nt

Emis

sion

s, k

g/yr Vehicle

HeatPowerPower/Heat

Over 95% Reduction

Note: criteria pollutants include NOx, CO, and hydrocarbons


Hydrogen Energy Station Proposed Future Work

Future energy stations need to evolve along with the vehicles.

Future WorkFuture Work

Compare cost and performance to baseline technologies

• Cost depends on vehicle and stationary FC production volume

ChallengesChallenges

Develop a design concept for larger scale production

• Much smaller packaging would facilitate acceptance in more locations

• Required stand off distances for hydrogen storage can be over 50 ft

Identify partners for commercialization • Need to obtain better perspective of benefits to federal fleets

• Strained economy limits new ventures• Code requirements are evolving• Deployment of hydrogen FCVs from manufacturers

presents a chicken/egg problem to potential energy station users

Evaluate barriers to hydrogen utilization


Hydrogen Energy Station Cooperative Efforts

A number of stakeholders are being contacted to determine their requirements and interest in energy stations.

StakeholdersStakeholders

AutomakersFuel cell manufacturerElectric utilitiesGovernment hospitalsMilitary basesGovernment fleetsEPACT fleets

Attend Fuel Cell Seminar Nov ‘02Made presentations on environmental impacts to CA Air Resources Board, South Coast AQMD, Blue Water Network, and othersSubmitted Paper to Dec ‘03 Fuel Cell Seminar

Outreach EffortsOutreach Efforts CommentsComments

“This (energy station) is the only way fuel cell infrastructure will ever work”

“Aren’t SOFCs more efficient for stationary applications?”

“We have to deal with Rule 21, for grid interconnection.”

“With the downturn in the economy we have to focus on our core activities.”

“If we could get a fuel cell car, this (energy station) would be a good idea.”

hydrogen technical analysis: energy station · revenue from power sales help overall economics in...

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