advanced onsite hydrogen generation for power plants_india_2011_.pdf

7/28/2019 Advanced Onsite hydrogen generation for power plants_India_2011_.pdf

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Advanced Onsite HydrogenGeneration Solutions

for Power Generating Stations


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Proton Energy Systems


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Company Highlights

Proton Founded in August of 1996 Shipped first HOGEN generator to NASA 1998 More than 1,500 HOGEN systems are in operation in

more than 65 countries.

Proton Energy Systems Assembly Floor,

Wallingford, Connecticut


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Global Presence

Over 10 years of exportexperience

Thousands of systemsshipped

65 countries Every Continent


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Global Support Worldwide Service and Support Team GCC Countries Middle East/ North Africa India Mexico Brazil China Europe Southeast Asia Australia

Regionally based Factory-Trained Dealers 24 Hour Technical Support Site Supervision Services Factory and/or Field Training In-House Code and Hydrogen SafetyExperts Dedicated Applications Engineer for Each

Project.


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India Support

MVS is a Proton partner in India Main Sales and Technical Service office in

New Delhi, India Factory trained engineering staff Installation, start up, and repair capabilities


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Same technology used for militaryIs used for commercial systems

Military Hardware Supplier

Bipolar PEM Electrolysis for Submarine Life Support

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U.S.A., France, and U.K. navies arereplacing their KOH electrolyzersWith PEM electroyzers supplied withProton PEM stacks


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Bipolar PEM & KOH Technology Comparison

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Electrolysis of Water, circa 1800:

2H2O(l) 2H2(g) + O2(g)

Hydrogen gas(H2) forms atcathode

Oxygen gas(O2) forms at

anode

William Nicholson, ca.1812Engraving by T. Blood after a

portrait painted by Samuel

Drummond (1765-1844)

Effect first discovered by William Nicholson, English chemist


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KOH MSDS Analysis


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KOH MSDS


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Two Main Types of Low Temp Electrolysis

Alkaline & Proton Exchange Membrane (PEM) Liquid electrolyte vs. solid membrane

O2

H2

Separator

Liquid Electrolyte(KOH)

(+) (-)

DC Power


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So What is Bipolar PEM Electrolysis?

Electrochemical Process that uses asolid electrolyte

Splits Waters base elements Zero Harmful Chemicals or Emissions Produces Hydrogen and Oxygen from

Electricity and Water

High Pressure (165 bar+) with nomechanical compressors

Very fast start and response times


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NafionMSDS

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NafionMSDS

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How Does Bipolar PEM Electrolysis Work?


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Technology differencesPEM Technology / KOH water electrolysisHydrogen Generation by PEM Technology Water

Electrolysis via HOGEN Hydrogen GeneratorsHydrogen Generation via Alkaline (KOH) type water

electrolysis

Does not contain any asbestos Some systems are known to contain asbestos

No special personal protective gear to maintain and operate Special personal protective gear needed to handle KOH

Can be installed in general purpose ventilated area, does notcreate hazard area classification per NEC (IEC) when

installed in accordance with IEC60079-10 Zone 2EMust be installed in a Class 1 DIV II Area

System continuous and automatic turndown capability in the rangeof 100% to 0% net product output.

Most systems do not have turn down ratio of 100% to 0%

Can be started and stopped indefinitely Every system stop shortens life of the system (corrosion)

Does not require nitrogen for inert purging Some require nitrogen for inert purging at shutdown and/or startup.


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Technology differencesPEM Technology / KOH water electrolysisSystem employs differentialpressure design (high pressure

hydrogen, ambient oxygen) to eliminate risks associated with:

Explosion of oxygen gas leaking into product hydrogen Handling/fire risk of high pressure oxygen Expensive oxygen monitoring equipment in product gas

System employs balancedpressure design (high pressure hydrogenand high pressure Oxygen) risks associated with:

Explosion of oxygen gas leaking into product hydrogen Handling/fire risk of high pressure oxygen Expensive oxygen monitoring equipment in product gas must be

designed for and managedThe only possible impurity of significance in product

hydrogen due to the principles of physics is H2OvPossible impurities of significant risk in product hydrogen stream

include: KOH, O2.

No need for back up power supply to safely shutdown Requires back up power system to safely shut down

System is integrated into a single package consisting of all controls,hydrogen production, rectifiers, and purification.

Most Systems consists of 3 separate packages consisting ofcontrols, hydrogen production, rectifiers, and purification.Sometimes these packages have to be located separately.

Rectifiers have to go into an unclassified area for example, away fromthe hydrogen production which is located in the hazardous area itcreates.


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PEM versus KOH Summary

PEM No hazardous materials or

chemicals

Contains high purity wateronly

Long component life Safe for operators and service

technicians

Easy to maintain and service,no caustic solution to drainand refill

Low Maintenance Typical maintenance less than

4 hours per year

Any repair can be completedin 1 hour or less

Caustic Caustic chemicals (KOH) required

Corrosive to components Possible asbestos content-

known carcinogen andbanned in many countries

Eye and skin hazard. Extremecaution required in handling

Special purification equipmentrequired

Overboard dischargespossible with expensivedamage to downstreamcomponents

High Maintenance Some require 39 hours of

maintenance Per year and

increase as corrosiondamages components

Process component repairmay require draining ofcaustic and extensivedowntime.


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PEM & KOH Maintenance

PEM Low Maintenance

Typical maintenance less than4 hours per year

Any repair can be completedin 1 hour or less

Failure to PerformMaintenance will result withsafe shutdown.

Caustic High Maintenance

Some require 39 hours ofmaintenance Per year andincrease as corrosiondamages components

Process component repairmay require draining ofcaustic and extensive

downtime.

Failure to PerformMaintenance can resultwith serious risk safety tolife and property.


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Bipolar PEM Technologyand

Systems DesignedFor

Power Plants

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The Technology

PEM (ProtonExchangeMembrane)

is at the heart of the technology

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The PEM Electrolysis Process

At the anode, water molecules aresplit using electricity, formingoxygen, and hydrogen ions.

Protons flow through themembrane, while the formedoxygen is released. Electronstravel through the circuit.

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The PEM Electrolysis Process

At the cathode, the electronsand hydrogen ions combine toform hydrogen gas.

Anode: 2H2O ---> 4H+ + 4e- + O2

Cathode: 4e- + 4H+ ---> 2H2

Overall: 2H2O ---> 2H2+ O2

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Membrane ElectrodeAssembly (MEA)

Cell stack

H2 Generator

Technology andSystems


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S Series HSeries StableFlow

HOGEN Hydrogen Generators Hydrogen Control Systems

TM

TM

Products for the Power Industry


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HOGEN Product Range

0.265, 0.53, 1.05

Nm3/hr @ 13.8 barg99.9995%, < 5 ppm H2O

HOGEN S-Series

2, 4, 6 Nm3/hr

15 or 30 barg99.9995%,


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C SERIES HOGEN Hydrogen Generator

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C-Series 10 Nm3/hr 20 Nm3/hr 30 Nm3/hr 30 bar g pressure 99.9998% purity, < 2ppm H2O, -72C Conforms to ISO 22734-1


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Front ViewDoors Open

Integrated Design Hazards Classification

Integrated design allows forsimple installation

Controls andRectification

HydrogenProduction


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C SERIES HOGEN Hydrogen Generator


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C SERIES HOGEN Hydrogen GeneratorFluids Enclosure


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C SERIES HOGEN Hydrogen GeneratorRectifier Enclosure

HOGEN S S iTM


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Features:200 240 VAC, 1phAir CooledFully Integrated DesignNetwork ReadyHydrogen:24 NM3/day production99.9995% purity-65 degrees C dew point15 barg

HOGEN S SeriesTM

Advanced Technology Means We do the Heavy


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Advanced Technology Means We do the HeavyLifting

We ship a product ready to go to work,not a container of parts

Fully assembled and tested Engineered and drop-tested packaging Easy placement and commissioning

Clean PEM Technology Safety MeansLower Engineering Costs

Low hydrogen inventory- ATEXcompliant

Unclassified Zone, Explosion-prooffixtures not required

No hazardous materials No Containment dams, emergency

showers, mixing equipment, disposalconsiderations.

cTUVus (UL and CSA equivalent), CE (PED, ATEX,LVD, Mach. Dir., EMC

HOGEN H SeriesTM


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Features:380 480 VAC, 3phWater CooledFully Integrated DesignNetwork ReadyHydrogen:2, 4, or 6 Nm3/hr99.9995% purity-65 degrees C dew point15/30 barg

HOGEN H SeriesTM


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Hydrogen Generator Interface Connections


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Hydrogen Generator Operator Interface

H d G R O I f


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Hydrogen Generator Remote Operator Interface


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Maintenance RequirementsCG Calibration & Air Filter Inspection/90 days

15 Minutes

Annual Maintenance Hardware & FilterChanges

~4 hours

Cost of Hydrogen Generation

$0.93 per 100 scf($0.35 per Nm3)(including maintenance & electricity $0.04/kWh)

HOGENH Series Generator

Typical Power Plant Implementation


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Typical Power Plant Implementation


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Integrated System Options for India

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StableFlow Hydrogen Control System


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The Physics Behind the SolutionAir is the most likely impurity to affect hydrogen densityAir is 14.4 times as dense as hydrogenExample:Hydrogen with a purity level of 97.0% and the balance of impurity being air at 3% will have the following affect on gasdensity.

[(0.97 x 1) + (0.03 x 14.4)] x 100 = 140.2 % change in density


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StableFlow - Mathematical Example

340 MW Generator

140 kW windage loss per % purity

8000 operating hours per year

1133 MWhr = $45,000 per year based $40/MWhrFor every 1% Purity Improvement & Stablized

with StableFlow HCS


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See complete articlesupplied titled, Seals

from Aerospace


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Windage loss per % H2 Purity


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Windage loss Curves


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The Physics Behind the Solution

As presented by Yokogawa

Effects of Hydrogen Purity

0

1000

2000

3000

4000

5000

88 90 92 94 96 98 100 102

% Volume concentration

Dollarsperda

Smaller units

Larger units


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97% AVG

99.9%

Hydrogen Purity

94

95

96

97

98

99

100

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

Number of days

%P

urity

Desired Purity

Actual Purity

StableFlow - Effect on PurityTM


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StableFlow - Effect on Purity & Dew PointTM


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StableFlow - Effect on Dew PointTM

VS

StableFlowTM


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Features:120 240 VAC, 1ph, 50/60HzFully Integrated Design4-20mA outputNetwork ReadyHydrogen control:> 99% purity< -20 degrees C dew pointStable Pressure

StableFlow


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2 x HOGEN H6m atNTPC Vindhyachal


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2 x HOGEN H6m atNTPC Vindhyachal

Mechanical and Electrical Connections


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Mechanical and Electrical Connectionsfor HOGENs at NTPC Vindhyachal

MechanicalConnec,ons:H2productat15barH2

ventatambient(noO2connec,onrequireddemin

waterdeminservicedrain

ElectricalConnec,ons:ACPowerremotemonitoring

viaEthernetcableremoteshutdownsignal

Power Plant Installation GE Energy, Qatar


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gy

Power Plant Installation Doha, Qatar


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Onsite Hydrogen GeneratorsAnd Chillers

Gas Storage System

,

Ras Abu Fontas

Hydrogen Compressor

Power Plant Installation Deming, NM


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Onsite Hydrogen Generator

Gas Storage System

g

Power Plant Installation Compostilla, Spain


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Hydrogen Control System

p , p

A Fully Integrated Design


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y g gThat Meets International Safety Standards

A HOGEN hydrogen generator

does not create a hazardousenvironment according to NFPAand ISO hydrogen safety codesand standards

Power Plant Installation Dickerson, MD


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Hydrogen Control System

Power Plant Installation Doha, Qatar


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Quatalum

Power Plant Installation Cairo, Egypt


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El Kureimat

Hydrogen Compressor


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Thank You

advanced onsite hydrogen generation for power plants_india_2011_.pdf

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